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1. Mod All weldpipe Rout All main Direction Forward Search do2 Replace do3 1 4 MoveL pl1 v100 z10 to0ol0 Set dol Reset do2 WaitTime 2 Replace Search Repl all OK Figure 33 Search amp Replace dialog when the program is selected e Press the function key Search to start the search The first match will be selected in the lower part of the window Press Replace to replace the selected text or press Repl all to replace all matches without having to confirm e Continue the search with Search e Press OK to end the search 8 38 User s Guide Programming and Testing 9 2 Mirroring The mirror function can be applied to any routine in a program Mirroring a routine means that a copy of the routine is created with all positions mirrored in a specific mirror plane The new mirrored routine will be given a new name a default name is proposed All stored data of type robtarget used in the routine will be mirrored and stored with a new name the old name ending with _m All immediate robtarget data shown with an in movement instructions will also be mirrored What does mirrored mean In general all data of the type robtarget used in the routine will be mirrored It makes no difference whether the robtarget data is declared as a constant which it should be as a persistent or as an ordinary variable Any other data e g of type pos pose orient etc will not be m
2. i A Figure 8 Mains switch After the system has been checked and no errors are located the following message see Figure 9 appears on the display Welcome To IRB 6400 0000 Base Ware OS 3 1 AL 1D ED PADDED ABB Robotics Products AB c Copyright 1993 Figure 9 The welcome window may vary slightly depending on the type and version of your robot User s Guide 4 15 Starting the System Basic Operation 4 16 User s Guide Basic Operation Working with Windows 5 Working with Windows In this chapter you will find out about the basics of working with windows The fol lowing example shows the window for Inputs Outputs manual handling of in and outputs 1 Press the Inputs Outputs window key see Figure 10 Figure 10 The Inputs Outputs application key both versions 2 The window for manual I O is now shown on the display as in Figure 11 The appearance of the I O list may vary depending on how the signals have been defined and how many I O boards there are in the system Menu keys gt File Edit View Window title Inputs Outputs All signals 3 OM Name Value Type T O list name 1 40 lt Line number dil dl DI di2 0 DI gripl 0 DO grip2 1 DO T O list grip3 1 DO grip4 1 DO progno 13 GO welderror 0 DO Cursor Function keys Figure 11 Window for manual I O handling When a digital outp
3. Special Jogging Robot pos Unit Robot x 1234 5 Motion Linear y 244 9 Current 4 i a position Q1 A a Coord Base Q2 0 0000 monet Tool tool0 Q3 0 0000 parameters Wobj wobj0 Q4 0 7071 Joystick lock None xzy Motion Incremental No 5 gt resulting from different World Base Tool Wobj joystick deflections 1 1 1 Menu Special Special 1 Align 2 Increments 3 Motion Supervision Command Used to Align Align the tool see page 6 9 Increments Specify the sizes of the user defined increments see page 6 14 Motion Supervision Turn Motion Supervision on off see page 6 5 User s Guide 18 3 The Inputs Outputs Window 2 The Inputs Outputs Window 2 1 Window Inputs Outputs Quick Reference File Edit View Inputs Outputs Name of All signals the I O list Name Value YP 4 64 dil 1 DI di2 0 DI gripl 0 DO x grip2 1 DO T O list ETE T s grip4 1 DO progno 13 GO welderror 0 DO 0 1 2 1 1 Menu File File 1 Print 2 Preferences Command Used to Print print the current I O list see page 7 8 Preferences make preferences in the Inputs Outputs window see page 7 4 User s Guide Quick Reference 2 1 2 Menu Edit Edit 1 Goto 2 Goto Top 3 Goto Bottom Command Goto Goto Top Goto Bottom 2 1 3 Menu View View Most Common All Signals Digital In Digital Out Analog Groups Safety I O Unit
4. 1 Start IN Order 0 1 CycleOn OUT Response 0 User s Guide 12 27 System Parameters To load and start a program Load a program from diskette or another mass storage device The program will then start from the beginning If a program is running execution will stop first Requirement Robot in MOTORS ON state and program control not occupied by any other resource e g external computers Signal sequence 1 Load IN Order 0 1 CycleOn OUT Response 0 To stop QuickStop StiffStop program execution Requirement Valid in all modes Signal sequence 1 Stop IN Order 0 1 CycleOn OUT Response 0 To stop at the end of the cycle Stops program execution when the complete program cycle has been executed Requirement Valid in all modes Signal sequence 1 StopCycle IN Order 0 1 CycleOn OUT Response i 0 12 28 User s Guide System Parameters To detect spontaneous execution stops Requirement Robot in AutoOn 1 MotorOn 1 and CycleOn 1 Signal sequence CycleOn OUT Response 0 There are three main reasons why stops occur 1 Program controlled exit stop or error in the program 2 Emergency stop 3 Safety chain broken due to reasons other than an emergency stop Detect case 1 with Error 1 Detect case 2 with MotorOn 0 CycleOn 0 EmStop 1 and RunchOK 0 Detect case 3 with MotorOn
5. Data 1 3 New counter _a counter_6 regl reg2 reg3 reg4 reg5 reg100 Next Func More Cancel OK Figure 18 The dialog box used to define data that is to be changed Only num data is shown in the list e Select the desired data e Select the next argument by pressing Next You must now specify the new value for the data For the purposes of this exercise we have chosen a constant value e g reg1 5 Use list to select a data instead of a numeric value e Using the numeric keyboard enter the value directly e Choose OK to confirm the input of the instruction The instruction is now ready for use User s Guide Calibration CONTENTS Page 1 Coordinate SY SECIS 6545 cc cesta cicslecdatecceensceeseecsaceeaecetiavee desde estaba ae 3 2 Coordinated AROS Sis csnsetusiceh covssunnetansess sush sunvectos teeseeudssananbssevaabsnscen acsbassatesotonecensesseusnseananen 5 2 1 External ARES generaliter eese lee sa cance geass acd E E EE 5 2 COOTCINAUON EE E E A E Re Ce Oe eC 5 3 Calibration fis cceccssscssseccecsccessacdevsadeseeessiustessogsucbersdcoseesnssuedeodags Sdessosussayedcocdedesieucavesdereeseieee 6 Salt What 1s Calibration senile are E el aaa E el 6 3 2 Viewing the calibration Stas cccssssseescvassdencyscavevaseiwy vies dasscesnstageeasteestnadaiecahen deeecaces 6 3 3 Checkins the calibrati entenia ance anensuaeenas ence aeons ates 7 3 4 Updating revolution counters
6. File Edit View Special Service Logs Log name Motion Message Date 1 1 50028 Jogging error 0810 20 11 20 Error number Heading Logs gt Displays all logs Figure 3 The Service Log Messages window displays all messages in the log e You can obtain more information on a specific message by selecting the message and pressing Enter or by choosing Edit Info 3 5 Erasing the contents of a log e Open the Log window by choosing View Log e Select the log to be erased e Choose Special Erase Log e Choose OK to confirm 3 6 Erasing the contents of all logs e Open the Log window by choosing View Log e If there are log messages displayed press the function key logs e Choose Special Erase All Logs e Choose OK to confirm 14 6 User s Guide Service 3 7 Updating the contents of a log automatically or by means of a command When you view a log message and a new message appears you have two choices you can either update the log automatically when the message appears or update the log using the function key Update The Update function key is only visible if there are more messages To update automatically e Choose Special Update log on Event To update on command e Choose Special Update log on Command 3 8 Avoiding normal error reports When trying to isolate faults in different hardware components you may not wish to be shown error alert boxes To p
7. d 3 Topic LO Sus nals soca osicssecsccvcesecessesesidavece tesceasan coaseanesucanssvecevecvecroavodecenauesuaucisenccosntenveeganians 9 be Detinne A S nicsia0 seancececatdat seataten un ccasenateena sence ancaseeeenet ance manaeeeas aS 9 3 2 Additional parameters for gateway field bus units 0 eee eee eeeeeeeeeeeneeeees 10 3 3 Defining input and output STS TVA sc ds ace ce cual sca cuins slndy tase guveo Saw eee rnse vos 12 3 4 Defining signal SOUPS jeassiea cess ancestor a E E E A ees 14 3 5 Defining Cross Connections ei secs cas e r A a a e aaa AEAEE seas 15 3 6 List all available I O Unit Types isisissasscacssseavaacitayscerssacieiawis seaceaauains a decosanasustacsvsned 19 Oot VO Data Speciticaons aioe tet a a a a A E 21 3 8 Defining syste inputs srren nner ae sgean iia 22 3 9 Defining system Outputs iiieoo eion eos aneirin arp S oae SEAR I rS 24 3 10 PLC Comm nication sisses tjian sinipi a aia tess 26 4 Topic Communication esssesssesssecesocesocesoocssocesocssoosssocesoccssocesocesoosesocesocessocesocsssossssessseee 31 4 1 Defining physical channels seseseseseesseseesseesseesseesseresseessseessressersseresseeesseesseesse 31 4 2 Defining Transmission Protocol sssesseessessseesseessssessseesseesseesseresseeesseessresseessees 32 4 3 Defining Application Protocol esseeessseesssessesssesssesessseesseessersserssseessseessesseessee 34 S Topic Controller ncssressrisessccsssstsssosuiessoossrees
8. eeeessesessesesseseresressessresressereresreesresese 4 3 2 Manual mode with reduced speed programming mode seeeseseeeeeeereeeeeeeee 5 3 3 Manual mode with full speed testing mode s snsssseesssessessesesseeessressees 5 4 Switching the Power Supply to the Motors On s esssesssocssocesoosesoeessccesocesooesoossose 5 BS Emergency Stops ciceecasscaceccxecseaksccastadevssencacenningetseeesteanscvato eee amenities 6 5 1 Activating the emergency stop button sisi 2s eet een we baal 6 5 2 Resetting after an emergency stop 2 6 ssccccncsesdsdecesscdssungnasa cede csadacssndesavedeanaderss 6 6 The Teach Pendant iiss cissoas sexcssascanssstvonsantats ssgvossstnasensenersoussesansetbesyeniacbeaesacoeuseiastone 7 6 1 Entering text using the teach pendant seeseseeseesesesreeresresresrersresreseresressessess 9 User s Guide 5 1 Starting up 5 2 User s Guide Starting up Starting up 1 Switching on the Power Supply Before switching on the power supply check that no one is in the safeguarded space around the robot e Switch on the mains switch The robot hardware is then automatically checked When the check is complete and if no errors have been detected a message see Figure 1 will be displayed on the teach pendant Welcome To IRB 6400 0000 BaseWare OS 3 1 AL ED ED PALE ABB Robotics Products AB c Copyright 1993 Figure 1 The welcome message after start up In automatic mode the P
9. Figure 23 Program structure If you open a program that program replaces the program in the robot s memory When a program is opened the main routine will be shown on the display with the first instruction in the main routine selected highlighted 7 1 Using the training program The training program is stored on the system diskette Controller parameters under the directory DEMO and is called EXERCISE 1 Turn the operating mode selector on the operator s panel to lt 250 mm s 2 Press the Program window key see Figure 24 Figure 24 The Program window key User s Guide 4 25 Selecting a Program Basic Operation If there is no program in the robot s memory the following window will appear Figure 25 otherwise you will see the program that is stored in the memory of the robot File Program Instr No Program to show Use the menu File to open or to create a new Program Figure 25 The Program window 3 Insert the Setup diskette into the disk drive at the front of the cabinet The diskette should be inserted as in Figure 26 eas ony eee i ee Pe Figure 26 Inserting the diskette 4 Press the File menu key see Figure 25 above The window in Figure 27 will appear IL OjsxSis a 5 2 New 3 4 Save Program Save Program
10. eee eseesseceseceeeeeeneeenaeenes 75 7 17 Activate notch filter for an external axis ccceccessseceeeeseeeeeeeesnenseneeecertenee 76 TAS Soft servo for external ARIS nis insin a aSa 77 7 19 Defining the joystick directions for the robot and external manipulator 78 7 20 Defining the joystick directions for a single external axis seeen 80 7 21 Defining kinematic parameters for general kinematics eee eee eeneeeeeeeees 81 Jit SELEY O PAU AMACLE BEA esau cect uat aust osetia E Gua oaadae sa Sedan T 83 123 CPU Opti Zann sinies teenies len len etal aE aeiia 84 7 24 Installation optimization of drive system parameterS eee eeeeeseceseeeeeeeeeees 86 12 2 User s Guide System Parameters System Parameters The system parameters describe the equipment and area of application of the robot sys tem e g I O names and the characteristics of the external axes 1 Changing a Parameter 1 1 Subdivision of parameters The available parameters are grouped together in a number of different topics These topics are in turn divided up into different types Topic Parameters that affect Controller Event routines etc Communication Serial channels IO Signals T O boards and signals Manipulator The robot and external axes TeachPendant Displaying data and access on the teach pendant Arc Welding Arc welding File name SYS CFG SIO CFG EIO CFG MOC CFG MMC CFG PROC CFG e To view all parame
11. Figure 5 A routine comprises declarations routine data instructions and an error handler The declaration specifies routine parameters among other things These are used to make the routine more generally applicable A routine that for example moves the robot a given distance in the direction of the tool can have that distance as a parameter This routine can then be called using different distances and thus can be used to move the robot different distances The error handler takes care of automatic error handling see Error Handling on page 52 3 2 The Program Routines window e Choose View Routines to open the window The window displays routines and if there is a function present also the type of data returned for that function see Figure 6 File Edit View Routine Special Program Routines WELDPIPE Routines In Module Name Type yp 4 6 cleangun errorout1 givedist num Value returned Routines main for a function weldseql weldseq2 New Decl Dupl Data gt Test Figure 6 The Program Routines window displays all routines in the program User s Guide 8 9 Programming and Testing 8 10 3 3 Creating a new routine e Open the Program Routines window by choosing View Routines e Press the function key New A dialog box appears displaying the name of the routine see Figure 7 The name is set to routineN where N is a number incremented each time a r
12. The number of digital outputs is out of range at board address d max outputs are d Check 1 Change the configuration for the board 71036 Name out of range DescriptionReason The number of characters in name s is greater than d characters or the name is missing Check 1 Give a new name that fits within the limits 16 92 71037 IO Cross connection fault DescriptionReason The signal s appears on both FROM and TO in the same chain Check 1 Correct the configuration for the cross connections where the signal above is connected 71038 IO Cross depth to high DescriptionReason The Cross connection in the same chain is too deep First signal name s Check 1 Make the Cross connection less deep 71041 Analog output overflow DescriptionReason Number of analog output for board s is greater than d Check 1 Reduce the number of analog outputs 71042 Analog inputs overflow DescriptionReason Number of analog inputs for board s is greater than d Check 1 Reduce the number of analog inputs 71043 Signal type error DescriptionReason The type specified for signal s can t be connected to specified board Check 1 Change to another type 2 Change to another board 71044 Physical signal overflow DescriptionReason The range of phsig or length or phsig and length for signal s is greater than d Check 1 Change the physical sig
13. Up and Down arrows Press to move the cursor up or down Left and Right arrows Press to move the cursor to the left or right Motion keys to select how the robot or other peripheral equipment should move when using the joystick during manual operation ne Motion Unit Press to jog the robot or other mechanical units Motion Type Press to select how the robot should be jogged l reorientation or linear 5 O Motion Type Axis by axis movement 1 axis 1 3 2 axis 4 6 Incremental Incremental jogging on off 4 12 User s Guide Basic Operation System Overview Other keys Stop Stops program execution O Contrast Adjusts contrast of the display Menu keys Press to display menus containing various commands Function keys Press to select the various commands directly lt x Delete Deletes the data selected on the display Enter Press to input data Programmable keys P1 P2 P3 P4 P5 Functions to be defined by the user User s Guide 4 13 System Overview Basic Operation 4 14 User s Guide Basic Operation Starting the System 4 Starting the System You are now going to turn the system on i e get it ready for programming running programs etc Before you switch the system on make sure that no one is inside the safeguarded space around the robot 1 Switch the mains switch on see Figure 8 The robot is then automatically checked A
14. 20080 Not allowed command Not allowed when axis is not commutated 20081 Not allowed command Not allowed when axis is not calibrated 20082 Not allowed command Not allowed when axis rev counter is not updated 20083 Not allowed command Not allowed when axis is not synchronized 20092 Not allowed command Not allowed in state System IO Start Blocked 20100 Teachpendant in ctrl A teachpendant application is in control of the requested resource program motion User s Guide Base Ware OS 3 1 20101 Teachp prg in ctrl The teachpendant programming window has focus and is in control of the program server Change to the production window and perform the command again 20102 Teachp joystick in ctrl The teachpendant joystick is in control of the motion server Release the joystick and perform the command again 20111 Teachp prg in ctrl The teachpendant programming window has focus and is in control of the program server Change to the production window and perform the command again 20112 Program 1 in ctrl The program server is in control of the motion server Stop the program and perform the command again 20113 Program 2 in ctrl The program server 2 is in control of the motion server Stop the program and perform the command again 20114 Program 3 in ctrl The program server 3 is in control of the motion server Stop the program and perform the command again 20115 Program 4
15. Figure 3 A positioning instruction is added directly to the program If the correct argument was chosen the instruction is now ready for use However we will continue and change the speed and zone size e Select the argument you wish to change v 00 in this example e Press Enter The dialog box used to program instruction arguments appears The selected argument is marked with a in front of it see Figure 4 The lower part of the box displays all available speed data that can be selected Instruction Argument MoveL v100 z10 tooll Speed v100 4 8 New vmax v5 v10 v20 v30 v40 v50 v60 v80 v100 v150 Next Func More Cancel OK Figure 4 The dialog box used to change the speed e Select the desired speed e Go to the next argument zone data by pressing Next All available zone data will be displayed see Figure 5 User s Guide 9 5 The programming language RAPID Instruction Argument MoveL v60 z10 tooll Zone z10 2 4 New fine z5 z10 z15 z20 z30 z40 z50 z60 z80 z100 Next Func More Cancel OK Figure 5 The dialog box used to change zone data e Select the desired zone size e Choose OK to confirm the change The instruction is now ready for use 1 2 Programming an offset Sometimes it is easier to define a position as an offset from a given position If for example you know the exact dimensions
16. e Press OK to confirm 6 10 User s Guide Jogging 2 5 Jogging the robot in the direction of the work object ei e Set the keys A to jog the robot in a straight line HH hd a e Select the field Coord see Figure 15 e Press the function key Wobj AD 4 9mm z 12 8 mm Q1 0 7071 Coord Wobj Q2 0 0000 Tool tool0 Q3 0 0000 Wobj wobj0 Q4 0 7071 Joystick lock None xz y Incremental No y9 gt World Base Tool Wobj Figure 15 Specify the coordinate system in the Jogging window The work object that was last used when jogging the robot or last used for program execution is automatically chosen If you want to change the work object e Select the field Wobj see Figure 16 1 0 7071 Coord Wobj Q2 0 0000 Tool tool0 Q3 0 0000 Wobj wob j0 Q4 0 7071 Joystick lock None xz y Incremental No 39 gt Figure 16 Choose a work object by selecting the field Wobj e Press Enter lt e Select the desired work object from the dialog box which subsequently appears on the display Wobj0 in the dialog box corresponds to the world coordinate system User s Guide 6 11 Jogging Select desired data in the list 1 2 wobj1 wobj2 wobj3 wob j4 New Change Define Cancel OK Figure 17 Changing or adding a work o
17. Make sure to let the transformer cool down before ordering Motors On again Check View Safety in the IO window and wait until the signal TRFOTMP equals 0 before ordering Motors On again 20252 Motor temp high Status active for over temperature in motors of manipulator Make sure to let the Motors cool down before ordering Motors On again Check View Safety in the IO window and wait until the signal PTC equals 0 before ordering Motors On again 20253 Ext device temp high Status active for over temperature in external device Make sure to let the Motors cool down before ordering Motors On again Check View Safety in the IO window and wait until the signal PTCEXT equals 0 before ordering Motors On again 20254 Power supply fan stopped Status active when fan in power supply not running Check Check the power supply fan hardware 16 34 20255 Panel Board voltage low Status active when Panel Board 24 V failed Check Check the Panel Board voltage 20260 Run control status fault Status conflict between motor contactors and run control Check Replace Panel Board 20261 Strings to long Description Reason Elog message number d Total String length d gt d characters Check 1 Reduce the total string length 20270 Access error Panel Module access error Check Examine your EIO configuration files 20280 Symbol conflict The signal s defined in the IO configuration conf
18. User s Guide 7 5 Inputs and Outputs 2 Changing Signal Values Robot equipment may be affected e g start to move or fall off if you change the value of a signal Before you do so make sure that no one is in the safeguarded space around the robot Incorrect operation can injure someone or damage the robot or other equipment 2 1 Changing the value of a digital output e Select the digital output e Choose the desired value using the function keys see Figure 4 File Edit View Inputs Outputs All signals Name Value Type 4 64 dil 1 DI di2 0 DI gripl 0 DO grip2 1 DO grip3 1 DO grip4 1 DO progno 13 GO welderror 0 DO 0 1 Figure 4 You can change the value of a digital output directly using the function keys 2 2 Changing the value of an analog output signal or a group of output signals e Select the signal and press Change see Figure 5 File Edit View Inputs Outputs All signals Name Value Type 4 64 dil 1 DI di2 0 DI gripl 0 DO grip2 1 DO grip3 1 DO grip4 1 DO progno 13 GO welderror 0 DO Change Figure 5 You can change a group of outputs or an analog output signal by choosing Change and entering a value using the numeric keyboard 7 6 User s Guide Inputs and Outputs A dialog box will appear which you can use to enter an arbitrary value e Specify the desired value using the numeric keyboard and press OK You can also change the value o
19. e Modify the position by pressing the function key ModPos e Move the robot along the track and repeat the steps above for the points Point 2 and Point 3 To calculate the track base frame e Press OK to calculate the track base frame for the selected mechanical unit When the calculation is finished a dialog like the one in Figure 9 will appear User s Guide Calibration el Track Base Frame Calculation Result Unit TRACK Calculation Log 1 10 Method n points n 3 Mean error 1 19 Max error 2 56 Cartesian X 63 05 Cartesian Y 16 12 Cartesian Z 98 00 File Cancel OK Figure 9 The result of a track base frame calculation The result of the calculation is expressed in the world coordinate system Field Description Unit The name of the mechanical unit for which the definition of base frame is to be done List contents Description Method Displays the selected track definition method Mean error The accuracy of the robot positioning against the tip Max error The maximum error for one positioning Cartesian X The x coordinate for the base frame x y z is the same as for the robot base frame Cartesian Y The y coordinate for the base frame Cartesian Z The z coordinate for the base frame Quaternion 1 4 Orientation components for the base frame The calculation result can be saved in a separate file for later use in a PC e Press the function key File e Specify a name and a lo
20. 1 Restart the system 71157 Invalid app type DescriptionReason Com Unit s has an unspecified Com app type named s Check 1 Check the Com app type against the one specified for the Com app 71158 Address out of range DescriptionReason The address of unit s is out of range Check 1 Change the address 2 Check the address syntax 71159 Signal Access illegal DescriptionReason Signal s The number of characters in Access s is greater than d or name missing Check 1 Give a new Access that fits within the limits 71160 Access level illegal DescriptionReason Signal s Access level s in group s is illegal Legal choices all man auto none Check 1 Give a new access level for group that fits User s Guide Base Ware OS 3 1 71161 Access name not found DescriptionReason Signal s The Access name s not found in EIO_USER_ACCESS Check 1 Define s in EIO_ USER_ACCESS or change Access name 71163 Signal on internal unit DescriptionReason Signal s is not allowed to connect to s because the unit is internal Check 1 Connect the signal to another unit 71164 Internal signal in cross DescriptionReason Signal s is not allowed to be cross connected to signal s Check 1 Make sure that none of the signals are internal 71171 Illegal I O Unit DescriptionReason The unit type s used by unit s is anon ABB device Check 1 Make sure that the I O Plus Option
21. 117210 Welding equipment error PCB supply voltage 15VB on Powersource Control Unit to high or to low Check Replace Powersource Control Unit 16 107 System and Error Messages 117211 Welding equipment error Long term difference between requested and actual weld current value Check Hardware problem in current servo sys tem Power source control board or inverter block or unnormal load conditions bad welding 117212 Welding equipment error Internal CAN communication failure CAN circuits in Powersource Control Unit is in WARNING state Check Change data several times or reset welding equipment with power switch If the error do not disappear check bus connections and or exchange Power source Control Unit 117215 Welding equipment error Powersource Control Unit has detected that a received internal CAN message was lost overwritten by a later message Check Reset welding equipment with power switch 117226 Welding equipment error Program execution error Watch dog in Powersource Control Unit program activated Check Reset welding equipment with power switch 117227 Welding equipment error Undocumented Powersource Control Unit error Check Request additional information from ESAB ABB 16 108 117228 Welding equipment error Undocumented Powersource Control Unit error Check Request additional information from ESAB ABB 117229 Welding equipment error Undocumen
22. 40252 Limit error Task 16s Error i when creating sdb entry for 16s Check An error occurred when the persistent was to be inserted into the shared database Probably the database is full 40253 Type definition error Task 16s Alias 16s of alias 16s not allowed Check Is is not possible to define an alias type equal to another alias type Instead define two alias types equal to the same atomic or record type 40254 Symbol definition error Task 16s gt ANYTYPE parameter 16s cannot be dimensioned Check Remove the dimension specification ANYTYPE includes array types 40255 Symbol definition error Task 16s ANYTYPE only allowed for parameter not for 16s Check Use another type 40256 Parameter error Task 16s alt must not be set for first optional parameter 16s in alternatives list Check Make sure that only the second and following in each list of excluding optional parameters are marked as alternatives User s Guide Base Ware OS 3 1 40257 Parameter error Task 16s REF mode parameter 16s cannot be dimensioned Check Remove the array dimension specification or change the mode of the parameter 40258 Parameter error Task 16s switch parameter 16s can not be dimensioned Check Remove the array dimension specification or change the data type of the parameter 40259 Parameter error Task 16s switch param
23. 7 8 Limiting the working space For certain applications movement about the robot s main axes must be limited in order to create a sufficiently large safety zone This will reduce the risk of damage to the robot if it collides with external safety arrangements such as barriers etc Movement about axes 1 2 and 3 can be limited with adjustable mechanical stops or by means of electrical limit switches If the working space is limited by means of stops or switches the corresponding software limitation parameters must also be changed If necessary movement of the three wrist axes can also be limited by the computer soft ware Limitation of movement of the axes must be carried out by the user 7 9 Supplementary functions Functions via specific digital inputs e A stop can be activated via a connection with a digital input Digital inputs can be used to stop programs if for example a fault occurs in the peripheral equipment Functions via specific digital outputs e Error indicates a fault in the robot system e Cycle_on indicates that the robot is executing a program e MotOnState MotOffState indicates that the robot is in MOTORS ON MOTORS OFF mode e EmStop indicates that the robot is in emergency stop state e AutoOn indicates that the robot is in automatic mode 8 Safety Risks Related to End Effectors 8 1 Gripper If a gripper is used to hold a workpiece inadvertent loosening of the workpiece must be p
24. A joystick is used to jog the robot It has three degrees of freedom which means that you can move the robot in three different directions simultaneously The robot speed is proportional to the joystick deflection the greater the joystick deflection the higher the speed but not faster than 250 mm s The joystick can be used irrespective of which window is open at the time You cannot however jog the robot in the following situations When the robot is in automatic mode O When the robot is in the MOTORS OFF state When program execution is in progress If any axis is outside its working range it can only be jogged back into its working range The function of the joystick can be read from and changed in the Jogging window Some of the settings can also be changed directly using the motion keys on the teach pendant see Figure 1 Robot Reorientation Axes 1 2 3 Q 1 3 Z O External unit Linear Axes 4 5 6 Figure 1 The indications next to the motion keys show the current settings The robot or external unit will start to move immediately you move the joystick Make sure that no one is standing in the safeguarded space around the robot and also that the motion settings for jogging are correctly set Carelessness can injure someone or damage the robot or other equipment 1 1 The Jogging window e Press the Jogging key to open the window The window displays the current mo
25. Check An argument corresponding to a required parameter must not be specified with the leading V character Change the optional argument into a reguired 40011 Argument error Task 16s Named required argument 16s at wrong place in argument list Check Check that the arguments are specified in the same order as the parameters for the routine being called 16 50 40012 Argument error Task 16s switch argument 16s cannot have a value Check An argument corresponding to a switch parameter may not be assigned a value Remove the value 40013 Argument error Task 16s Too few arguments in call to routine 16s Check A routine call must supply values for all required parameters of the routine being called Add more arguments to fit the parameter list 40014 Argument error Task 16s Too many arguments in call to routine 16s Check Remove arguments so that no arguments are supplied in excess to those defined by the parameter list of the called routine 40015 Data declaration error Task 16s Array dimension must be gt 0 value is 1 Check Array dimensions must be positive Change the dimension expression 40016 Data declaration error Task 16s Too many dimensions in array definition Check An array may have at most 3 dimensions Rewrite the program so that no more than 3 dimensions are needed 40017 Type error Task 16s Indexed data 18s 18s i
26. Controller Communication IO Signals Manipulator Arc Weld Teach Pendant OU BRWNHE All Topics Command Controller Communication IO Signals Manipulator Arc Weld Teach Pendant All Topics Used to go to the first line in a list go to the last line in a list go to a specific line in a list view information about the latest modifications made see page 12 5 change pass codes see page 12 46 Used to view the parameter of the Controller topic see page 12 37 the parameter of the Communication topic see page 12 31 the parameters of the IO topic see page 12 9 the parameters of the Manipulator topic see page 12 53 the parameters of the Arc Weld topic see RAPID ProcessWare Arc Ware the parameters of the Teach Pendant topic see page 12 45 all topics see page 12 3 User s Guide Quick Reference The System Parameters 7 1 4 Menu Types Content showing the types connected to the chosen topic User s Guide 18 31 The System Parameters Quick Reference 18 32 User s Guide INDEX A Add 9 14 add an instruction 8 16 Add New Parameters 12 7 Add or Replace Parameters 12 7 Align 6 5 6 9 All Topics 12 3 All Types 8 46 analog output change manually 7 6 approach point 10 29 argument 8 13 add optional 8 34 change 8 33 arithmetic expression 8 18 Arm parameters 12 54 12 55 12 56 Arm check pnt parameters 12 58 Arm load parameters 12 57 array data
27. Dyn step 1 f Dyn step 2 f Axc step 50195 Independent move error Joint s cannot be moved in independent mode 50196 Calibration error Points 0 and 1 too close 50197 Calibration error Points 0 1 2 on a line or point 2 too close to points 0 or 1 Check User s Guide BaseWare OS 3 1 System and Error Messages 50198 Calibration error Internal error Check Report the occurance 50199 Calibration error External joints have been moved during calibration Check Avoid moving external joints 50200 Torque error Torque error due to high speed Check 1 Check load data 2 Reduce speed 50201 Orientation outside reach The error of the programmed orientation exceeds the acceptance limit Check 1 Adjust robtarget orientation 2 Adjust check orientations of currently used frames tool frame base frame user frame object frame 50202 No dc link configurated The dc link s and drive unit s used by joint s is not connected to same serial link Check Select another dc link Change serial link for drive unit Set the parameter no_dc_link to TRUE 50203 Measurement node used The measurement node for joint s is already used Check Select another node 16 85 System and Error Messages 50204 Motion supervision Motion supervision triggered for joint s Possible causes collision incorrect load definition external process forces Check If load
28. Instruction Argument WaitDI lt EXP gt lt EXP gt Signal 1 4 New dil di2 di di4 di5 di6 di7 di8 di9 dil0 dill Next Func More Cancel OK Figure 9 The dialog box used to define an input e Select the desired input e Choose Next to define the next argument i e the value of the input e Enter the input value using the numeric keyboard e Press OK to confirm User s Guide 9 9 The programming language RAPID 3 2 Waiting a specific amount of time Time to wait WaitTime 0 5 e Choose IPL1 Various e Select the instruction WaitTime A dialog box appears in which you can enter the time see Figure 10 Instruction Argument WaitTime lt EXP gt Time 1 1 New Next Func More Cancel OK Figure 10 The dialog box used to define WaitTime e Enter the time using the numeric keyboard e Press OK to confirm 4 Controlling the Program Flow 4 1 Calling a subroutine A call instruction contains the following information information on the routine to be called information on any arguments The routine name Arguments if any routinel reg3 23 When this instruction is executed the called routine will be executed Following this execution will return to the calling routine see Figure 11 9 10 User s Guide The programming language RAPID main routine routinel routine set dol ee F
29. Move the cursor using the right arrow key File Edit View IPL1 IPL2 Program Instr EXERCISE main 1 4 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 49 The fine argument is selected 2 Press Enter The window in Figure 50 appears User s Guide 4 45 Changing a Program Basic Operation Instruction arguments MoveL v300 fine tool0d Zone fine 1 5 New fine zi Z5 z10 ZLS z20 230 z40 z50 z60 z80 Next Func More Cancel OK Figure 50 Dialog box for programming instruction arguments 3 Move the cursor to z10 4 Press Enter and the fine argument will change to z10 5 Then press OK The instruction has now changed to z10 6 Move the cursor so as to select the complete instruction see Figure 51 13 3 Adding instructions You are now going to add a movement instruction to the program after the first instruc tion The Program Instr window in Figure 51 should now appear on the display File Edit View IPEL IPL2 Program Instr EXERCISE main 1 4 Movek WS00 210 togIrg MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 51 Program window 1 Press the Copy function key to copy the fir
30. MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Start FWD BWD Modpos Instr gt Figure 38 Window for starting the program The program can now be started Make sure that no one is inside the safeguarded space around the robot 6 Start the program by pushing in the enabling device and pressing the FWD function key see Figure 38 When the program has started the robot will carry out one instruction then it will stop Press FWD to initiate the next instruction press again for the next one and so on The window in Figure 39 is displayed during the execution of the program Exec Test Program Run EXERCISE main Speed 75 Running Continuous Event Log Executing Figure 39 Window during program execution 7 Go through all the program instructions step by step Press FWD repeatedly after the robot is in position 8 Ifyou press FWD when the program comes to the final instruction the program will start from the beginning again 9 Let the robot move to position number 4 see Figure 34 User s Guide 4 33 Starting the Program Basic Operation 4 34 10 11 12 13 Move in the same way as before the cursor to the Running field and change to Cycle execution Move the cursor back to the program Start the program by pressing Start When Cycle is selected
31. Then select the desired instruc tion and press Enter 5 A window like the one in Figure 56 appears Instruction Argument WaitTime lt EXP gt Time 1 2 New regl reg2 reg3 reg4 reg5 Next Func More Cancel OK Figure 56 Dialog box for entering arguments 6 Type 3 on the numeric keyboard to get a wait time of 3 seconds 7 Press OK The window like the one in Figure 57 appears File Edit View IPL1 IPL2 Program Instr EXERCISE main M C 1 5 6 MoveL v300 210 tool0 1 MoveL v300 z10 tool0 2 Comment MoveL v300 fine tool0 3 Load MoveL v300 fine tool0 4 Unload WaitTime 3 5 WaitDI MoveL v300 fine tool0 6 WaitDo 7 WaitTime 8 WaitUntil Copy Paste OPtArg ModPos Test gt Figure 57 The Program Instr appears on the display 8 Press Edit Hide IPL to remove the pick list 9 Now test run the program again using the Program Test window Choose continuous execution INFORMATION The Edit menu includes a number of functions which can be used to edit the program see Figure 58 User s Guide 4 49 Changing a Program Basic Operation Undo Latest action VTEW TELI IPL2 T Cut Program Ij Undo EXERCISE main 2 Copy L Cut 3 Paste 2v COPY 5 6 MoveL v3 tool 4 Goto Top MoveL v3 tool0 5 Goto Bottom MoveL v3l tool0 6 Mark M
32. User Level sele Confirm select parameter Confirm and press Enter Description The name of the function to be authorised cannot be changed Required user level to be able to execute the function can be Operator Service and Programmer Should the function be confirmed before it is executed Yes or No ct parameter User Level and press Enter e Choose appropriate value and press OK e When finished press OK to confirm the change Authorise SystemParameters e Choose Topics TeachPendant e Choose Types Authorise SystemParameters All possible functions will be displayed as shown in Figure 24 File E dit Topics Types System Parameters TeachPendant Authorise SystemParameters Function User level Confirm 1 3 Launch Service No Change Code Service Yes Delete Inst Service Yes Figure 24 Au Function Launch Change Code Delete Inst thorise System Parameters Description To authorise the opening of the window To authorise the change of pass codes To authorise the deletion of a parameter e To change user level and or confirm see Defining authorisation on page 47 Authorise Program e Choose Topics TeachPendant e Choose Types Authorise Program User s Guide System Parameters All possible functions will be displayed as shown in Figure 25 File Topics Types System Parameters TeachPendant Authorise Progra
33. Vv s 7 o s 1 N Pid 1 o p2 MoveL pl v200 z10 tooll MoveL p2 v100 fine tooll MoveJ p3 v500 fine tooll Figure I Positioning the robot Apart from these arguments a positioning instruction may contain optional arguments e g arguments used to specify the positioning time See the appropriate instruction in RAPID Reference Manual for more details e Jog the robot to the desired destination position e Call up the instruction pick list by choosing IPL1 Motion amp Process The program and specified pick list will then appear in the window see Figure 2 File Edit View IPL1 IPL2 Program Instr WELDPIPE main Motion amp Proc 1 1 lt SMT gt ActUnit DeactUnit MoveC MoveCDO MoveJ MoveJDO MoveL MoveLDO More y ODI HAUBPWNHEe Copy Paste OptArg ModPos Test gt Figure 2 The dialog box used to program positioning instructions e Choose the desired instruction by pressing the appropriate numeric key The instruction will be added directly to the program as illustrated in Figure 3 The arguments are set automatically 9 4 User s Guide The programming language RAPID File Edit View IPL1 IPL2 Program Instr WELDPIPE main Motion amp Proc 1 MoveL v100 z10 tooll ActUnit DeactUnit MoveC MoveCDO MoveJ MoveJDO MoveL MoveLDO More y ODAIHDHUAWNHE Copy Paste OptArg ModPos Test gt
34. reg5 regl reg2 1 strings e g TPWrite Producing ae H SBOE AND NOT TRUE XOR FALSE Boolean data Boolean function 8 18 Figure 13 Logical expression User s Guide Data Value Function ile Figure 14 Arithmetic expression TAD i M DIV Programming and Testing Programming an expression Expressions are programmed by pressing the function key More in the instruction argument dialog box see Figure 12 Expressions can be entered or changed directly in the upper part of the dialog box see Figure 15 by doing any of the following move the cursor to the left or right using ArrowLeft _ or ArrowRight delete what is marked by the cursor by pressing Delete Q add digits in front of the cursor using the numeric keyboard ay Expression 1 2 counter_a counter_b regl reg2 reg3 reg4 Text Func Content Cancel OK Figure 15 The Expression dialog box gt E Data functions and operators can be selected in the lower part of the dialog box Press t if needed select the desired alternative and press Enter Enter text by pressing Text A dialog box appears in which using the function keys and the numeric keyboard you can enter text If the desired information is not in the
35. s appears both as FROM and as TO Check 1 The same signal can not be given for both FROM and TO 71022 Physical max too high DescriptionReason Signal s The physical max value gt 3f Check 1 Change value in configuration 71023 Physical min too low DescriptionReason Signal s The physical min value lt 3f Check 1 Change value in configuration 71024 Physical value too high DescriptionReason Signal s Current value 1f gt Maxvalue 1f Value set to Maxvalue Check 1 Change physical max value in configuration 71025 Physical value too low DescriptionReason Signal s Current value 1f lt Minvalue 1f Value set to Minvalue Check 1 Change physical min value in configuration 16 91 System and Error Messages 71026 Logical value too high DescriptionReason Signal s Current value 1f Maxvalue 1f gt Value set to Maxvalue Check 1 Change logical max value in configuration 71027 Logical value too low DescriptionReason Signal s Current value 1f lt Minvalue 1f Value set to Minvalue Check 1 Change logical min value in configuration 71033 Dig input out of range DescriptionReason The number of digital inputs is out of range at board address d max inputs are d Check 1 Change the configuration for the board 71034 Dig output out of range DescriptionReason
36. with the specified name 40274 Parameter error Task 16s Unknown parameter transfer mode i for 16s Check The specified parameter transfer mode is not one of IN VAR PERS INOUT or REF Use corresponding REAL_SYMPARMOD x 40275 Symbol definition error Task 16s Unknown symbol definition type i Check The symbol definition type tag does not specify one of the allowed symbol types REAL_SYMDEF_x 40276 Symbol definition error Task 16s Initialization function may not be specified for shared variable 16s with per task value Check Remove initialization function install variable in all tasks or make variable value shared 40301 I O error Task 16s Permission denied file name 39s 40302 I O error Task 16s No such file or directory file name 39s 40303 I O error Task 16s No space left on device file name 39s User s Guide Base Ware OS 3 1 40304 I O error Task 16s I O error file name 39s Check One of Permission denied write protected No such file or directory No space left on device 40321 Load error Task 16s Module loaded with path 40s is active Check A module containing routines or data that are still active cannot be erased 40322 Load error Task 16s RAPID syntax error s in file 40s Check The source file to be loaded contains RAPID syntax errors Correct the source file The sy
37. 18s for right operand of or lt gt operator not value or semi value type Check The and lt gt operators may only be applied to expressions of value or semi value type If comparisons are to be made special type specific predefined functions are needed 40058 Type error Task 16s TEST expression type 18s not value or semi value type Check The TEST instruction may only be applied to an expression of value or semi value type If comparisons are to be made special type specific predefined functions are needed 40059 Data declaration error Task 16s Place holder for value expression not allowed in definition of named constant Check Complete the data declaration or change the data name to a place holder User s Guide BaseWare OS 3 1 System and Error Messages 40060 Data declaration error Task 16s Place holder for array dimension not allowed in definition of named constant or variable Check Complete the data declaration or change the data name to a place holder 40061 Routine declaration error Task 16s Place holder for parameter array dimensions not allowed in definition of named routine Check Complete the parameter declaration or change the routine name to a place holder 40062 Name error Task 16s Place holder for parameter name not allowed in definition of named routine Check Complete the routine declaration or change the routine name
38. 3 2 8 A function that interconnects a guard s or a device s and the robot controller and or power system of the robot and its associated equipment Hold to run control ISO 10218 EN 775 3 2 7 A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released 3 4 User s Guide Safety 5 Safe Working Procedures Safe working procedures must be used to prevent injury No safety device or circuit may be modified bypassed or changed in any way at any time 5 1 Normal operations All normal operations in automatic mode must be executed from outside the safe guarded space 6 Programming Testing and Servicing A A A The robot is extremely heavy and powerful even at low speed When entering into the robot s safeguarded space the applicable safety regulations of the country concerned must be observed Operators must be aware of the fact that the robot can make unexpected movements A pause stop in a pattern of movements may be followed by a movement at high speed Operators must also be aware of the fact that external signals can affect robot programs in such a way that a certain pattern of movement changes without warning If work must be carried out within the robot s work envelope the following points must be observed e The operating mode selector on the controller must be in the manual mode position to render the enabling device operati
39. 4I Choosing a Tottini a E I aS 8 12 4 2 The Program Instr WindoOW s sssessssssssssseseessereesseseesssserssssereessereesssseessssere 8 12 4 3 Whatis an Instruction asninn aaa E E Ea EE te 8 13 4 4 Getting more information about an instruction sesssessssseesseessessereseeesseee 8 14 5 Programmi oissiisiisosisdrsssosossapssscasossosossisotsssi ta osoase soassa tosssn tb issi tovs eisses taasis 8 14 5 1 Choosing from the instruction pick List eee eeeeeeeeeeseeeneeceeeeeseeeeseeeaeens 8 15 5 2 Adding an INSIMIC HON Fe a ehh BOE AG BE 8 16 5 3 EXPTOSSIOMNS lt iicdis shea Saidedite sighed A A E R ERE E 8 18 5 4 Moving and copying instructions sssesseessessseeesseeessetssressersseresseeesseesseesse 8 21 6 R nnin Proer aris cc iicesceccisastes aes ceeiaacssceatctassatinsestlaalesetaiintacdbescipatidixincscaaccennsbinte 8 21 User s Guide 1 3 6 1 Program GxeCUtiOn iiesissscavaicisecestsaneasea a aTe EE OTE EAN ETER 8 21 6 2 The Program Test WOW Cassie ea Evils Sila eed Tus Gat eda nice Goh aleadine 8 22 6 3 Choosing the speed correction wdc A renedees dues caaccecgasas ancsnaedussdueas teas ncdouasoeaceaseads 8 22 6 4 Choosing the execution mode 45 coi 5 cs Mas Bae nee eees 8 23 6 5 Starting program execution v4 vs3 cdscsscdcaes cassadcsclscdeds nncvaseeaed cadasesecdenaededatacestaces 8 24 6 6 Stopping program execution wis jccstia ewe cades Aa bid segceib eet easetee 8 25 6 7 Where will the programm Start c
40. 5 1 Activate delayed safeguarded space StOP ecceeescecsseeeeeeeeecseeeeceteeeesteeeesaes 12 37 5 2 Activate Hold To Run Control c 20 54 25 SRA 12 37 5 3 Defining event rutines iens sncsnnennsi nnii nn iiSi 12 38 5 4 Specifying regain distanc eS ees sts soa Gating ah Aas ER 12 39 5 5 System MISCET AME OUS oer aiot e ges ages e o oie atni STEE 12 40 5 6 Automatic loading of modules and programs cceeececeeeeeeeeeeeceteeeesaeees 12 41 5 7 Defining multitasking sic1 ccscisnscccaseseanszevstesvecedvadacds snczecoanoccadeed peaeenawasecvenesens 12 42 6 Topic TeachPendant ooeoesooeoesosoossssossssocsessocecesssecesssoossssoocessosecesssocssssoossssossse 12 45 6 1 Defining Optional Packages siicsccccucseiesasincgetdsdecgssageeesedy eadagtan vada deaaetaosensene 12 45 6 2 Defining File TH XtenSiOi e E a A A a E i E aE a e 12 45 6 3 Defining authorisation and confirmation sssssseesssesseesseresseeessesseesseessee 12 46 6 4 Activation of Limited ModPos Function sesessesesseseseeresseseresressersresrresreseese 12 49 6 5 Programmable Key Sis snsrcnresoressun seas r E E ESEE 12 50 6 6 Defining Running Mode Settings sssesessesesseessessseesseresseeesseessresseesseesseee 12 51 7 Topic Manip l tor gs cecce cscs cues csoatesdataaceensstencecnseenceacaeeena eel eoentae eR 12 53 7 1 Defining the commutation offset and calibration offset of the motors 12 53 7 2 Defining the range of movement and calib
41. A module included in the robot s program and which is transferred when copying the program to a diskette for example A compound data type A subprogram Local data that can only be used in a routine The instruction that will be executed first when starting pro gram execution A point at which the robot stops before it continues on to the next point A module that is always present in the program memory When a new program is read the system modules remain in the program memory The settings which define the robot equipment and proper ties configuration data in other words Tool Centre Point TCP The point generally at the tip of a tool that moves along the Trap routine Variable Window Zone 20 8 programmed path at the programmed velocity The routine that defines what is to be done when a specific interrupt occurs Data that can be changed from within a program but which loses its value returns to its initial value when a program is started from the beginning The robot is programmed and operated by means of a number of different windows such as the Program window and the Service window A window can always be exited by choosing another window The spherical space that surrounds a fly by point As soon as the robot enters this zone it starts to move to the next position User s Guide
42. Error in axis comp memory Check Replace robot computer board 33308 Error in axis computer Check Replace robot computer board 16 39 System and Error Messages 33309 Error in axis computer Check Replace robot computer board 33310 Error in axis computer Check Replace robot computer board 33311 Axis computer Current ref loopback error Check Replace robot computer board 33312 Axis computer error RUNNING DRVELT signal error Check 1 Replace robot computer board 2 Check drive system boards 33314 Axis computer error Check Replace robot computer board 33315 Axis computer error Check Replace robot computer board 33316 Axis comp err loopb comm Axis computer error loopback comm error Check Replace robot computer board 33320 Axis computer error Error reported by Axis computer Check Replace robot computer board 33321 Axis computer error Uncorrect VME vector generated at test Check Replace robot computer board 33401 Over writing mea system Over writing of output data to measurement system f Check Reload system Replace robot computer board Replace measure board 16 40 33402 Over writing drive sys Over writing of output data to drive system f Check Reload system Replace robot computer board Replace drive unit 33403 Over writing mea system Over writing of input data from measurement system f Check Reload system Replace robot computer board Rep
43. Linear track motion FREE_ROT Rotating external axis EXT_POS Used internally TOOL_ROT Used internally e Choose Types Joints and specify under parameter Logical axis the logical number of the axis in the RAPID program Example Logical axis 10 will then correspond to the field eax_d in a data of the type robtarget e Choose Types Arm and specify the arm characteristics for the axis Parameter Description Positive limit Upper limit for the axis work area in radians or metres Negative limit Lower limit for the axis work area in radians or metres e Choose Types Acc data and specify the arm performance for the axis Parameter Description Nominal acceleration Axis acceleration in radians s If the value specified is too high the motor will reach the torque limit Nominal deceleration Axis deceleration in radians s If the value specified is too high the motor will reach the torque limit e Choose Types Transmission and specify the following Parameter Description Transm gear ratio Gear ratio between motor and axis Example For a linear axis 21 43 denotes that when the axis moves m the motor rotates 21 43 radians Rotation movement Denotes whether the axis is of the rotating type Yes or linear type No Transm high gear The integer value of the numerator of the transmission gear ratio Only used for independent joints Transm low gear The integer value of the denominators of the transmission gear
44. Special Special 1 Define Coord 2 Go to selected position Command Used to Define Coord define a tool work object or program displacement see Chapter 10 Calibration Go to selected position go to a selected position 18 14 User s Guide Quick Reference The Program Window 3 6 Window Program Data Types File Edit View Types Program Data Types WELDPIPE 5 6 All data bool num Data types gt fooldata wobjdata All Data 3 6 1 Menu Types Types 1 Data 2 Used Types 3 All Types Command Used to Data call up all data of a selected type Used Types call up only those data types that are used All Types call up all data types see page 8 45 User s Guide 18 15 The Program Window Quick Reference 3 7 Window Program Test File Edit View Special Program Test WELDPIPE main Test runnin lemmas 30 g Running Continuous parameters 1 26 Program pointer gt gt Init data counter 0 Go to start position Instructions MoveL pstart v100 FINE gripper WaitUntil DInput ready 1 Start Set startsignal open_gripper Start FWD BWD Modpos Instr gt Go to the Program Instr window 18 16 User s Guide Quick Reference 3 7 1 Menu Special The Program Window Special 1 Move Cursor to PP 2 Move PP to Cursor 3 Move PP to Main 4 Move PP to Routine 5 Call
45. Stopped Speed 75 Running mode Continuous 2 39 MoveL pl v500 z20 tooll Program pointer 5 moveL p2 v500 z20 tooll i MoveL p3 v500 z20 tooll Program list Set dol Set do2 Start FWD BWD 4 1 1 Menu File File 1 Load Program Command Used to Load Program load a program see page 11 4 4 1 2 Menu Edit Edit 1 Goto 2 Start from Beginning Command Used to Goto go to a specific instruction Start from Beginning go to the first instruction in the program see page 11 7 User s Guide 18 19 The Production Window Quick Reference 4 1 3 Menu View View 1 Info 2 Position Command Used to Info display the program in the lower part of the window Position tune a position see page 11 8 18 20 User s Guide Quick Reference The FileManager 5 The FileManager 5 1 Window FileManager File Edit View Options FileManager Current unit gt f1p1 WELDINGS TEST Current directory Name Type Date Latest change 2 12 ise Go Up One Level PROC1 Program 1993 05 28 i PROC2 Program 1993 05 09 Files gt PROCFUNC Program Module 1993 05 01 WDATA Program Module 1993 05 01 WTOOLS Directory 1993 05 01 RESULTS Directory 1993 06 01 Up gt 5 1 1 Menu File File 1 New Directory 2 Rename 3 Copy 4 Move 5 Print File Command Used to New Directory create a new directory see page 13 5
46. The signal given in parameter s is write protected for RAPID access Check Select other user signal or change the access mode for the signal 40674 I O access error The signal given in parameter s is not write protected for user access from TP or RAPID Check Change the access mode to system type for the signal in the I O configuration 40700 Syntax error Task s Syntax error Ps 40701 Program memory full The task s has only i free bytes in its user space Check Remove some other module and try again 40702 File not found 40s The file path or the file name is wrong or the file doesn t exist 40703 Load error 40s The program module couldn t be loaded Check The program module have some errors User s Guide Base Ware OS 3 1 40704 UnLoad error AOs The program module couldn t be unloaded The reason could be Module not loaded with Load instr Not same file path as used for Load Check The program module must have been loaded with the instruction Load The file path and name must be the same in the UnLoad and Load instruction 40705 Syntax error Task s Syntax error Ps Check More syntax errors will follow this 40706 Loaded error The program module is already loaded Check The module name in the head of the file 40s already exists in the program memory 40707 T O Unit name invalid Task s The unit name 40s doesn t exist
47. Vendorld 75 VendorName Vendor Name DeviceType 7 ProductId 334 ProductName Product Name MajorRev 2 MaxDigin 6 MaxDigout 6 MaxAnin 0 MaxAnout 0 Some devices may respond incorrectly to commands sent from the robot controller during connection establishment The robot controller will then generate the error message 71102 DeviceNet incompatible This can be avoided by explicitly specifying that the controller should use a more trivial method for connection establishment This is done by adding the line DeviceDriver DNGeneric to the configuration file User s Guide System Parameters EIO_UNIT_TYPE Name typename Vendorld 75 VendorName Vendor Name DeviceType 7 DeviceDriver DNGeneric ProductId 335 ProductName Product Name MajorRev 2 MaxDigin 76 MaxDigout 6 MaxAnin 0 MaxAnout 0 3 7 I O Data Specifications The names of I O signals units etc have a maximum limit of 16 characters Each name must be unique in the topic IO Signals T O signals connected to a simulated I O unit cannot use Pulse Delay or Filter A maximum of 20 I O units including simulated I O units can be defined A maximum of 10 simulated I O units can be defined Pollrate for I O units has the range Minimum 10 ms Maximum 10 seconds Step 10 ms A maximum of 512 signal names including user signals and group signals can be defined Filter P
48. You can however move the parameter using Move up one step och Move v down see Figure 8 Routine definition Name Type routinel function In Module USER Data type num See aE Name Data type Req Alt Mode 1 2 parami num In param2 num 1 In New Move Move Cancel OK Figure 8 The dialog box used to define parameters e Change the name and characteristics of the parameter by selecting the appropriate field then Press Enter appears and specify the desired alternative in the dialog box that Choose an alternative using the function keys Field Name Data type Required Alt Mode Description The name of the parameter max 16 characters The data type of the parameter Specifies whether the parameter is compulsory Yes or can be omitted No at a call marked with in the list Non compulsory parameters can be mutually exclusive i e they cannot be used simultaneously in the instruction To input the first of these parameters press the function key First and to input the last one press Tail Specifies whether the parameter can only be read IN or whether it can be read and changed in the routine NOUT e Add any additional parameters maximum 16 parameters To remove a parameter select it and then press Delete lt x e Choose OK to confirm Tip Itis sometimes easier to create a new routine by duplicat
49. an error message will be given Avoid motion instructions in the routines For STOP QSTOP a motion instruction in the corresponding event routine will result in an error It is advisable to keep the rou tines short and quick A maximum of four routines may be specified for each system event and each task multitasking The same routine can be used in more than one event If there is a Stop or a Break instruction in some event routine the routine will be executed from the beginning at the next event The task s available are dependent on the type Tasks Limitation for POWER ON RESET and QSTOP event The specified event routine cannot be executed if the task program has semantic errors reference errors etc If this is the case the system will generate an error 5 4 Specifying regain distances Maximum distance for a regain movement the distance from the current robot position to the last executed path This can be set both for start in manual mode and for start in automatic mode A regain movement will begin when program start is ordered and before the program continues with the instruction that was interrupted due to a stop request If the regain distance exceeds the specified max distance an error message will occur e Choose Types Regain distances The operating modes will be listed see Figure 18 File Edit Topics Types System Parameters Controller Regain distances Mode Tcp_dist Tcp_rot 1 2 MA
50. cally e Choose Types Event Routines All defined event routines will be displayed see Figure 17 File Edit Topics Types System Parameters Controller Event Routines Event Routine Task 1 4 STOP STOP ROUTINE MAIN POWER ON RESTORE_IO MAIN Predefined but could be modified START SYS_ RESET MAIN Predefined and should not be RESET SYS_RESET MAIN removed Add Figure 17 Certain events can start routines automatically e Select the event routine to be changed and press Enter or add a new one by pressing Add e Define the system event and the routine assigned to it also select which task the definition is for Press OK to confirm The following types of system events are available System event Description POWER ON The robot is restarted warm start from the teach pendant or by power on START Execution is started from the beginning of the program RESTART Execution is started from the position where is was stopped STOP The program was stopped Note A delayed stop after current cycle will not execute the routines connected to this state QSTOP The robot was quick stopped emergency stop RESET The old program was erased The specified routine must be a procedure without any parameters The routines should be in a system module at least the routines for the RESET event 12 38 User s Guide System Parameters If the robot cannot find the specified routine
51. error s used in the parameter s in type s named s is not defined Check Use another one that is defined or define the used one For internal names see moc_chk log 16 80 50103 Num error in manipulator The orientation defined by quaternions including s in the type s named Ps is not normalized SQRSUM 1 Check Check the quaternions and or recalculate them For internal names see moc_chk log 50104 Num error in manipulator The parameter s in type s named 5 is not s Check Check the value For internal names see moc_chk log 50128 Manipulator error Terminating the topic check for manipulator due to earlier errors Check Correct the reported errors and run topic check again 50130 Synchronization failed Synchronization failed for joint Ps Check Make a new synchronization Restart System 50131 Calibration failed Calibration failed for joint Ps Check Make a new calibration Restart System 50132 Commutation failed Commutation failed for joint s Check Make a new commutation Restart System 50133 Test signal error No test signals are available for the master robot User s Guide Base Ware OS 3 1 50134 Corr vector warning Sensor correction vector calculations failed due to previous error 50135 SoftAct not possible Soft servo is not possible to activate 50137 Fine poi
52. following settings could then be applicable Physical Max 10 V Physical Min 0 V Logical Max 500 A V Logical Min 0 A V 12 13 System Parameters Filter Passive Filter Active Inverted Store The time in millisecs that a digital input signal must be zero before the robot acts on the signal change 100 ms to 32 s The time in millisecs that a digital input signal must be 1 before the robot acts on the signal change 100 ms to 32 s If two signals are connected to the same physical channel the filter time for these signals must be the same Set to YES if the digital signal shall be inverted i e if logical 1 should be set on the output as 0 If set to YES the digital outputs will be stored at a power failure and restored when the system is powered up again It should be noted that the value is connected to a logical signal If more than one logical signal is connected to the same physi cal signal an unexpected value may be obtained In such cases this parameter should be set to NO Maximum number of user defined signals including group signals 512 Signals connected to a simulated unit Type eip000 can not use Delay Pulse or any time related instruction only clean set and reset of digital input signals 3 4 Defining signal groups Digital signals can be grouped together and handled as if they were one signal The value of such a signal will thus be a positive integer that is
53. is installed 8 Arcweld error messages 110001 Gas supervision Check Check the welding equipment 110002 Water supervision Check Check the welding equipment 110003 Arc supervision Check Check the welding equipment User s Guide BaseWare OS 3 1 System and Error Messages 110004 Voltage supervision Check Check the welding equipment 110005 Current supervision Check Check the welding equipment 110006 Wirefeed supervision Check Check the welding equipment 110007 Wirestick supervision Check Check the welding equipment 110008 Arc ignition failed Check Check the welding equipment 110009 Schedule transfer error Check Define a weld schedule strobe input 110010 Schedule transfer error Check The schedule port was busy with previous transfer 110011 Process stopped Check Process was stopped by digital input 110012 Arc fill ignition failed Check Check the welding equipment 110013 Torch supervision Check Check the welding equipment 110021 Gas supervision Check Seam name 16s Time from weld start 16s min Check the welding equipment 16 101 System and Error Messages 110022 Water supervision Check Seam name 16s Time from weld start 16s min Check the welding equipment 110023 Arc supervision Check Seam name 16s Time from weld start 16s min Check the welding equipment 110024 Voltage supervision Check Seam name 16s T
54. low gear The integer value of the denominators of the transmission gear ratio Only used for independent joints Example For a rotating axis with high gear 100 and low gear 30 has a transmission gear ratio of 100 30 3 333333 For both manipulator axes and external axes the working area can be increased up to Manipulator Work area radians arm side IRB 1400 1885 IRB 2400 1 8 1885 IRB 2400 1 5 1571 IRB 4400 1260 IRB 6400 943 External axes 1256637 motor side e Choose Types Arm and specify the arm characteristics for the axis Parameter Description Positive limit Upper limit for the axis work area in radians or metres Negative limit Lower limit for the axis work area in radians or metres 7 7 Defining arm load The performance of the robot will be negatively affected if the arm load is not defined When more than one load is mounted on one and the same arm the total weight and the position of the centre of gravity must be calculated All loads mounted on the upper arm are related to axis 3 including loads on the rotating part e Choose Topics Manipulator e Choose Types Arm load User s Guide 12 57 System Parameters 12 58 Parameter Description Name The name of the arm load e g armload_1 max 16 characters Mass The mass of the arm load in kg Mass centre x The mass centre specified using the coordinate system Mass centre y of the arm in m See the example in Figure 27 Mass cen
55. num pos pos and orient orient Check the types of the operands 40023 Instruction error Task 16s Cannot transfer control into another instruction list Check Make sure that the label is located in the same instruction list as the GOTO instruction at the same or an outer level It is not possible to jump into a program flow instruction 40024 Type error Task 16s Illegal type 18s for left operand of binary or operator Check The allowed types for the operands of the operator are num pos and string for the operator num and pos Check the type of the operand 40025 Type error Task 16s Illegal type 18s for operand of unary or operator Check The allowed types for the operands of the and operators are num and pos Check the type of the operand 16 51 System and Error Messages 40026 Type error Task 16s Illegal type 18s for right operand of binary or operator Check The allowed types for the operands of the operator are num pos and string for the operator num and pos Check the type of the operand 40027 Type error Task 16s Illegal type 18s for left operand of P DIV or MOD operator Check The only allowed type for the operands of the DIV and MOD operato
56. ratio Only used for independent joints Example For a rotating axis with high gear 100 and low gear 30 has a transmission gear ratio of 100 30 3 333333 e Choose Types Drive unit and specify the following User s Guide Parameter Use drive unit type Unit position Node Max current A System Parameters Description Current type of drive unit Denotes the physical location in the cabinet Denotes the node on the drive unit to which the axis is physically connected Denotes the max current of the drive node Max thermal current A Denotes the max thermal current of the drive node Data for drive units Drive unit type Node Max current A Max thermal current A DSQC 346A 1 3 25 1 6 2 3 25 1 6 3 1 5 1 0 DSQC 346B 1 6 7 3 2 2 3 25 1 6 3 1 5 1 0 DSQC 346C 1 11 3 5 3 2 11 3 5 3 3 6 7 4 0 DSQC 346G 1 29 7 16 5 2 36 8 20 0 DSQC 358C 2 36 8 20 0 Positions of drive units in the drive system Drive unit position of 0 3 0 drive system 12 2 gt Figure 32 Drive system as seen from the front of the cabinet e Choose Types Motor type and specify the following Parameter Polepairs ke V rad s Max current A rms Phase resistance Ohm User s Guide Description Number of pole pairs for the motor typically 2 or 3 Nominal voltage constant induced voltage phase to phase Max current without irreversible demagnetisation Stator phase resistance half the res
57. s cccsisvsuesiastsdencsndvacaedsssdeedoans seaces te beneendunsaancnevenceesnass 8 4 Base Frame for the ROW Ob sssscsscsisssensssasephcschasadbicossecnacossconssoncocassbaseodageboosusconsconesesseeeseoas 9 4 1 Defining the Base Frame for the KODOU s cccceientintiecer ete eeietienmcinres 9 5 Coordinated track MOON since cissccevociassecsesisenssnoeseassbsedesdecseaoseasoddssdsouaveanevaaseadonsesoiesootacs 12 5 1 How to get started with a coordinated track MOTION e eee eeseceseeeeeeeeeeeeaeees 12 5 2 Defining the Base Frame for a track motion 0 ceeeceeeeceeceeeeeceeeeeceeeeeceteeeeeteeeees 12 6 Coordinated external axes e sesseseesossescosessossesossossesossossessossesossossesossossessossesossossssoesssse 16 6 1 How to get started with a coordinated moveable user coordinate system 16 6 2 Defining the User Frame for a rotational axis Single eee eeeeeeeeeeeeeeeneeeneeees 17 6 3 Defining the User Frame for a two axes mechanical unit Method 1 20 6 4 Defining the User Frame for a two axes mechanical unit Method 2 23 7 Defining TOONS ssicssicsissccacivensexisinsdnaacseavenavasstesvanasavnaasvavesiabussbuanesedsouasbeaseaawestuvesssasaassveouras 28 TA Creating a mew tool sicisashicgeiesy grenno e E a R nus E EES SEEE 28 7 2 Manually updating the TCP and weight of a tool ssssseseseseeeesessseeresressereresresse 29 7 3 Methods of defining the tool coordinate system sssess
58. see page 14 11 User s Guide 18 23 The Service Window 6 1 2 Menu Edit 18 24 Edit 1 Goto 2 Goto Top 3 Goto Bottom 4 Info Command Goto Goto Top Goto Bottom Info Quick Reference Used to go to a specific line in a list go to the first line in a list go to the last line in a list view information about selected log messages see page 14 6 User s Guide Quick Reference 6 1 3 Menu View View The Service Window 1 Log 2 Date amp Time Calibration Commutation BaseFrame Ou AUW Two Axes Definition System Info Command Log Date amp Time Calibration Commutation BaseFrame Two Axes Definition System Info User s Guide Used to display the different logs see page 14 5 set the date and time see page 14 3 calibrate the robot see page 14 8 commutate the motors see The Product Manual Repairs calibrate the base coordinate system see Chapter 10 Calibration calibrate the base coordinate system for a two axes manipulator see Chapter 10 Calibration display system information see page 14 9 18 25 The Service Window 6 2 Window Service Log Quick Reference File Edit View Special No of messages Service Log Time of most recent eles ee message Name Latest 4 9 Common 10 0810 20 30 32 Operational status 20 0810 20 25 14 System 0 Hardware 1 0810 20 30
59. see page 8 7 create new programs see page 8 6 save programs on mass storage see page 8 28 save programs on mass storage with new names see page 8 28 print the program see page 8 29 make preferences in the Program window see page 8 60 check that the program is correct see page 8 21 erase the program from the program memory save a module on mass storage see page 8 58 save a module on mass storage with a new name see page 8 58 The Program Window 3 2 2 Menu Edit Edit Quick Reference Cut Copy Paste Mark Value ModPos COMO WANA UU PWD BE Undo Latest action Goto Top Goto Bottom Change Selected Search Show Hide IPL Command Undo Cut Copy Paste Goto Top Goto Bottom Mark Change Selected Value ModPos Search Show Hide IPL Used to perform an undo on the latest action possible to undo in selected window see page 8 36 cut selected lines to the clipboard buffer see page 8 21 copy selected lines to the clipboard buffer see page 8 21 paste the contents of the clipboard buffer into a program see page 8 21 go to the first line see page 8 30 go to the last line see page 8 30 select several lines see page 8 30 change an instruction argument see page 8 33 show the current value for the selected argument see page 8 50 modify a position see page 8 31 search for replace a specific argument see page 8 37
60. serial link to drive system d Accumulated errors since warmstart d Check Restart start controller Check serial link 39234 Drive System Error Axis computer has detected transmission error from serial link to drive system d Accumulated errors since warmstart d Check Check serial link 39235 Drive System Error Axis computer has detected a checksum error when transmitting parameters to drive unit for joint s Check Restart controller Replace Drive unit Replace robot computer 16 47 System and Error Messages 39236 Drive System Error Wrong drive unit type detected for joint s s found when expecting s Check Check modify configuration Replace drive unit 39237 Drive System Error Axis computer has detected too many communication absent errors from serial link to drive system d Errors since warmstart d d absent transmission of d detected Check Restart start controller Check serial link 39238 Drive System Error Axis computer has detected transmission absent error from serial link to drive system d Accumulated errors since warmstart d Check Check serial link 39301 External Drive Error High DC voltage detected by external drive unit joint s Check See documentation for Atlas DMC FBU Check inkomming mains Check replace shunt resistors Check replace External Drive Unit 39302 External Drive Error High motor temperature detected by
61. set within s to s according configuration in the system parameters 40618 Argument error Argument s contains an illegal interrupt number Check Input interrupt number is illegal because it has not been allocated by the instruction CONNECT CONNECT do allocation and connection of interrupt number to trap routine 40619 Argument error Argument s contains an interrupt number which is already in use for other purpose Check Before reuse of an interrupt variable again in the program cancel old interrupt generation and interrupt number with instruction Delete 40622 Argument error The value of argument Time in Timer is too low for cyclic interrupts User s Guide Base Ware OS 3 1 40623 Argument error The value of argument Time in ITimer is too low for single interrupts 40631 Instruction error Too many move instructions in sequence with concurrent RAPID program execution Check Edit the program to max 5 MoveX Conc in sequence on the basic execution level of the program 40632 Instruction error No move instructions with concurrent RAPID program execution are allowed within the StorePath RestoPath part of the program Check Edit the program so it does not contain any MoveX Conc instructions within the StorePath RestoPath part of the program 40633 Reference error Trigg parameter no s reference to undefined trigg data Check Define trigg data by executing instruction Tr
62. ss sssessessseeesseesseesseesseessseessseesseese 3 3 1 Menu IPL1 shows different instruction pick lists 3 3 2 Menu IPL2 shows different instruction pick lists 3 4 Window Program Routines c ce cecceeeecceeeeeeeeeteeeesteeeesaes Al Men ROUUME i west cas cnadeers isisi 342 MEN SPeClal GeGk ee eee Cee BE Ee 3 5 Window Program Data i 5 cccccssissicsasastecasasassactversdcntaseceeneed Dodo Mei Mat ans ethene quote tees een cct naa E eigakks 3 52 Menu Specials Tititi ka 3 6 Window Program Data Types sessseesseessessseeesseeesseessees 3 6 1 Menu Typ S ni iniga 3 7 Window Program Test s 0 402 44 0 on oa 3TA Men Sp cial ninne en n 3 8 Window Program Modules ccceecceseseceesseceesteeeesteeeeees 3 8 1 Menu Modes cciacscossed icsececs sthsecetiasniaa hsssdneaseniadews 4 The Production Window cccsccsscsssssscesscsscssscesssssssessoeees 4 1 Window Production yy scscsselaesssstusesssetavevsassahedactonsastevaeheosaass AA SP Meni File nienn e aE Al Meni Bit Gu G Se a a n a 4153 Menu Vie Ws sissies Setcsats nnen R 5 The FileManager gis seis csucesccssa seek cuvnsavaacyy guepcaany casvacoweatucavecerbcavnees 5 1 Window Pile Manager x oisc cisatsdocncessueneeadctaeenttaosncesavesnes baaes User s Guide Quick Reference Quick Reference 5 1 1 Menu Fienie iasi iiia n re EE RE EEE EA E EE ETE 21 Jl 2 Menu Edit steeen cl ols cle at a E N 22 DES Men VIC W enaena e a a A a
63. tooll pointer MoveL p3 v500 z20 tooll Set dol Program list f Set 902 Start FWD BWD Figure 42 The Production window in auto mode 3 Press the MOTORS ON button on the operator s panel 4 Start the program with the Start function key 5 Stop the program with the STOP button on the teach pendant 6 Switch back to lt 250 mm s For further information see Chapter 11 Production Running in the User s Guide User s Guide 4 37 Automatic Mode Basic Operation 4 38 User s Guide Basic Operation Errors 11 Errors A window displaying an error message appears whenever there is any type of error see Figure 43 Category of error Error code number Error 50028 Motion Jogging error Jogging was made in wrong direction when Reason for error IS a joint was out of working range A Message log 50028 Jogging error 0810 09525 50 Check OK Figure 43 Example of a window displaying an error message Error code number A number unique to each error Category of error Assigns errors to groups relating to the type of error Each category has its own code number series e g Operator errors 6001 6999 Reason Describes the reason for the error in plain language For more information regarding hardware faults see the User s Guide 16 Error Management Message log Indicates the most recent errors The error indicated on the first line is d
64. transmission to from serial measurement system d Check Check connections cables for serial measurement system Check shieldings Check for high electromagnetic disturbances along cable run to robot Replace measure board or robot computer User s Guide Base Ware OS 3 1 39101 Drive System Error Temperature too high on DC link drive system 0f Check Check cooling fan s Check AC voltage to DC link Modify user program Replace DC link 39102 Drive System Error Shunt resistor overload drive system 0f Check Too much deceleration Modify user program Check AC voltage to DC link Replace DC link 39103 Drive System Error DC link incoming mains not valid drive system 0f Check Check voltage from Motor On contactor Replace DC link 39104 Drive System Error DC link voltage NOT OK drive system 0f Check Check voltage from Motor On contactor Replace DC link 39105 Drive System Error 15V out of limit on DC link drive system 0f Check Check 15V from power supply Replace DC link 39110 Drive System Error Unknown type code for dc link s Read typecode d when expecting d Check Replace dc link Check serial link User s Guide BaseWare OS 3 1 System and Error Messages 39111 Drive System Error Wrong type detected for de link s Ys found when expecting s Check Check modify configuration Replace dc link 39201 Drive System Error Reset from dr
65. will be listed 60031 Incompatible file The version of the configuration file is not compatible with this system Check Check the version of the configuration file 60032 Cannot calc user frame It is not possible to calculate a user frame with the selected approach points Check Select new approach points as accurate as possible User s Guide BaseWare OS 3 1 System and Error Messages 60033 Cannot calc object frame It is not possible to calculate an object frame with the selected approach points Check Select new approach points as accurate as possible 60034 Volume is not aviable 60035 Can not save disk is full 60036 File not found 60037 Cant open create file No file descriptor aviable 60038 Invalid number of bytes 60039 File already exists 60040 Illegal name 60041 Can not delete root 60042 Not file 60043 Not directory 60044 Not same volume 60045 File directory is read only 60046 Root directory if full 60047 Directory is not empty 60048 Bad disk 60049 No lable 60050 Invalid parameter 60051 No contig space 60052 Can not change root 60053 File descriptor obsolete 60054 Deleted 16 89 System and Error Messages 60055 No block device 60056 Bad seek 60057 Internal error 60058 File directory write only 60059 Disk changed 60060 No disk in driver 7 IO amp Communication error messages 7100
66. 0 CycleOn 0 EmStop 0 and RunchOK 0 To reset an emergency stop Switches the robot back to MOTORS OFF state after a spontaneous emergency stop Requirement Robot in automatic mode after an emergency stop The safety chain must be closed by resetting the emergency stop Signal sequence 1 ResetEstop IN Order 0 EmStop OUT Response 0 1 RunchOK OUT Response 0 Continue by switching the power to the motors back on User s Guide 12 29 System Parameters 12 30 RunchOK Indicates that the robot is back to MOTOR OFF state after a spontaneous safety chain stop Requirement Robot in automatic mode and spontaneous stop case 3 see above Signal sequence Wait until the RunchOK is high the safety chain is closed RunchOK OUT Response 0 Continue by switching the power to the motors back on User s Guide System Parameters 4 Topic Communication The following parameters are found under the Communication topic Specification of physical channels Transmission protocols Application protocols NFS Application protocol Remote Mounted disk Y J Transmission protocol XON XOFF SLIP TCP IP Ld y I Physical channels La A 422 ETHERNET Figure 13 The following combinations of application protocols transmission protocols and physical channels are possible The boxes with a thick frame can be an endpoint ofa configu
67. 1 Restarts aller a st p cies tienen ie as a Rene ant eed ela 5 2 Starting a program from the beginMing eee eee eeeceeeceeeeeeneeceeeceseesseeeeaeesnaeens 7 6 Stoppin the PLO STAM i vsiisicssccvecesveecvacsnseveeeossausceesunessessvarncsnveesaceusevevesesvtcssosenvsesstsvonessten T T UIE POSTON assesses cceatent cata a ees ees oa eee D Op rator LAO 95 ies Fi yc cae pccsiich bey ssa ceacsnustaece nec bnscos ce conceussencaeo aaa dane mrss REPT OD User s Guide 11 1 Production Running 11 2 User s Guide Production Running Production Running The Production window appears automatically on the teach pendant display when the power is switched on and the operating mode selector is in the Auto position You can also call it up by pressing ir and choosing Production 1 The Production Window The Production window is used to start and stop program execution see Figure 1 File Edit View Production Info CAR_LIN1 lt Program name Routine Main Status Stopped Speed 75 Running mode Continuous 2 39 Program list Set dol Set do2 MoveL p1 v500 220 tooll Program pointer gt MoveL p2 v500 z20 tooll MoveL p3 v500 220 tooll Start FWD BWD Figure 1 All production runs are controlled from the Production window Before starting the program check the program name to see that it i
68. 3 5 Window Prostam Data drie ve Saude vas Weslo a e E pun E E E 18 13 3 6 Window Program Data Types ssseessseeesseessesssessseessstesseessersseresseessseessrese 18 15 3 7 Window Prograny Vests aioe See e Sl a a Bo 18 16 3 8 Window Program Modules cesscccesececssececsscceceeccecseceecseeceeseeeeseeeenaees 18 18 A The Production Window ez ccciceccsseccensiccucsset ccipcccedsaecentcd cedetbecbveceesancetucesstsesceunceces 18 19 4l Window Production a rier oet e e E a aa AE aO ess 18 19 5 The File Manager icccoddssdescsnsaddensucsccadesussdeusthedccescdsscetedsaatdeeduestsacuieisddaatvesstacsveldeases 18 21 5 1 Window File Manager cii sscsvcceassceesesdiavacdennseecbanvesasectadenccuaniecedenedeedbeavansceesers 18 21 6 The Servic WVU OW ccssscesnactsscouidsscocccases setenasescanecos eessen sios cosenabaaconscepaessmeticnsss 18 23 Gh Grete ral MENUS recta cen E cece Noi leek esterase enc eth ae 18 23 62 WINDOW SOT VICE L0G os 5s soa eS Sc easiest cai AE E AE 18 26 6 3 Window Service Calibration ii 2 550c ssasaeesdeccaseasdsbadevessdendsscesaasndessaecenstecasvecs 18 27 6 4 Window Service Commutation scsi adage ottuegelen gstet cates lan otetestan open ee 18 28 7 The System Parameters s scccsiescacssivscccodavecesesssanesucavcocsveuesevessenveccencossnaucavoacersancesve 18 29 7 1 Window System Parameters sseeesseseeseeeseeseesessresressessresressresesreesreseeseresee 18 29 User s Guide 1 11 19 Special Function
69. 32 Log list Program 0 Motion 3 0810 19 15 12 Operator 4 0809 12 30 00 Process 0 Msg gt Displays the messages in selected log 6 2 1 Menu Special Special 1 Erase Log 2 Erase All Logs 3 Update log on Event Command Used to Erase Log erase contents in selected log see page 14 6 Erase All Logs erase contents in all logs see page 14 6 Update log on Event update the log directly when a message is sent the 18 26 command is changed to Update log on Com mand when selected which means that the log is not updated until the function key Update is pressed see page 14 7 User s Guide Quick Reference The Service Window 6 3 Window Service Calibration File Edit View Calib Service Calibration Unit Status 1 4 a Robot Synchronized Calibration Manip1 Synchronized status Manip2 Synchronized Trackm Synchronized 6 3 1 Menu Calib Calib 1 Rev Counter Update 2 Fine Calibrate Command Used to Rev Counter Update update the counter see Chapter 10 Calibration Fine Calibrate calibrate using the measurement system see the Product Manual Repairs User s Guide 18 27 The Service Window Quick Reference 6 4 Window Service Commutation File Edit View Com Service Commutation Unit Status 1 4 Robot Commut ated Manip1 Commutated Status Manip2 Commutated Trackm Commutated 6 4 1 Menu Com Com 1 Commu
70. 39212 Drive System Error DC link voltage higher than allowed detected by drive unit joint s DC link voltage s V Check Check inkomming mains Check replace shunt resistors Check replace DC link 16 46 39213 Drive System Error Critical over voltage on DC link detected by drive unit joint s DC link voltage s V Check Check inkomming mains Check replace shunt resistors Check replace DC link 39214 Drive System Error Low DC voltage detected by drive unit joint Ys Voltage s V NOTE This error will be disabled until next MOTOR ON Check Check inkomming mains Check program Check konfiguration Check replace DC link 39215 Drive System Error Too big difference in 3 consecutive current references to drive unit joint s Check Restart system Check replace resolver Check serial link drivesystem 39216 Drive System Error Too big difference in 3 consecutive rotor positions to drive unit joint s Check Restart system Check replace resolver Check serial link drivesystem 39217 Drive System Error Current error PWM ratio bigger than allowed Drive unit joint s DC link voltage s V Check Check DC voltage Check configuration Check motor cables User s Guide Base Ware OS 3 1 39218 Drive System Error Broken motor cabling detected by drive unit joint s DC link voltage s V Check Check motor cables 39219 Drive System E
71. 50088 Restart not possible It is not possible to restart the path due to a previous error Check Move the program start point and start anew movement 50089 Weaving changed The ordered weaving is not achieved due to high weaving frequency not allowed shift of weave method or that SingArea Wrist is used with wrist weave Check Increase weave length or period time Don t shift between arm and wrist weave Use SingArea Off with wrist weave 16 79 System and Error Messages 50091 Restart not possible Restart no longer possible Change of unit state made restart of program impossible Check Move the program pointer and start a new movement 50092 Axis computer comm error Incorrect response from axis computer Check Check motion configuration parameters Check axis computer hardware 50094 ServoTune not possible Tuning is not implemented for the specified Joint 50095 Cannot access joint Cannot access external joint Check configuration and activation of external Joints 50096 ServoTune not allowed Tuning is not allowed for the specified joint 50100 Manipulator error There are more configuration or numerical errors in motion domain Check Correct previous ones and try again 50101 Manipulator config error 5 is not free for the param s in type s named hs Check Use another one For internal names see moc_chk log 50102 Manipulator config
72. 7 iis Inputs Outputs Printing Data to Print All Signals Add Signal Info No Print Only to File No Yes No Cancel Print Figure 7 You can specify the extent of information and the destination e In the field Add Signal Info specify how much you want to print Press No to print the list Press Yes to print other information about the signals such as their configuration e Select the destination in the field Print Only to File Press No to output to the printer connected to the robot Press Yes to save the list in a file An additional line with the filename will be displayed If you want to change the filename select it and press Enter J e Start the print out by pressing Print e Press OK to confirm 7 8 User s Guide Programming and Testing CONTENTS Page 1 Creating a New Progr aim yiticcesssccncepsaticvstnctadeeiansetandstinceans Gace ae a eR ate ee 5 1 1 W hatis a programi deceit eee ea ae E E Saeed EREE KEENER 5 1 2 Th PHO Sr aT WNdoW ceneni ienna Gach E E S aea 6 1 3 Creating anew programi sesonon a a EE 6 1 4 Loading an existing Prograin i icissscccsccassscsssstecesdccdssnsversa cosscedasssucssusesscatnanseadcoantes 7 2 Defining Tools and Work Object ssesssessocesooesoocssoesssocesocecoosssocsssecssocesocesoosessesssesesocee 7 3 Creating New Routines seescseccoccsoeesoeossceccosesoeesooosscoccocecossecoessocecssoecos
73. 8 48 assignment 9 14 authorization 12 46 automatic mode 9 5 4 B base coordinate system define 12 61 jogging 6 6 BaseFrame 10 9 10 13 10 18 10 20 BWD 8 23 C Calibration 10 6 calibration offset 12 53 12 54 12 78 12 80 12 81 calibration position define 12 54 Call Routine 8 26 Call Service Routine 8 27 calling a subroutine 9 10 change argument 8 33 data 8 50 User s Guide displacement frame 10 43 10 44 instruction 8 29 optional argument 8 34 tool 10 29 10 31 work object 10 37 10 38 Change Pass Codes 12 47 Check Program 8 21 choose routine 8 12 Clear 9 14 collision detection 6 5 12 55 commutating 14 9 commutation offset 12 53 12 54 12 78 12 80 12 81 Compact IF 9 11 confirmation define 12 46 constant 8 45 Content 8 20 Controller parameters 12 37 coordinate system 4 22 coordinated motion 12 63 Copy File Manager 13 6 instruction 8 21 copy data 8 50 8 58 files 13 6 routine 8 11 8 58 CPU Optimization 12 84 create data 8 47 directory 13 5 displacement frame 10 43 module 8 56 program 8 6 routine 8 10 tool 10 28 work object 10 36 Cross Connections define 12 15 C Start 14 11 Cut instruction 8 21 20 1 D Data 8 45 data 8 45 change 8 50 create 8 47 declaration 8 51 delete 8 52 duplicate 8 50 8 58 Data Types 8 46 Date amp Time 14 3 Declaration data 8 51 module 8 56 routine 8 35 Decr 9 14 define tool 10 28 Define Coord displacement frame 10 44 tool 10 31 work obj
74. 99 USER reg5 45 USER New Decl Dupl Instr Test Figure 39 All data of a given type are displayed in the Program Data window To choose a new data type in the Program Data window e Open the window Program Data Types by choosing View Data Types The Program Data Types window opens and displays all data types that have at least one declared data see Figure 40 File Edit View Types Prog DataTypes WELDPIPE 5 7 All data bool clock num robtarget tooldata wobjdata Data types gt All Data Figure 40 The Program DataTypes window is used to change the data type e Select the desired data type and press Enter If the desired type is not displayed in the window you can call up all data types by pressing All type or choosing Types All Types All data can be chosen by selecting All data Data for a selected type can be chosen by pressing Data or Enter 8 46 User s Guide Programming and Testing 10 3 Creating new data e Open the Program Data window by choosing View Data The Program Data window is opened and displays all data of the type last selected If you wish to create data of a type other than that displayed choose View Data Types select the desired data type and press Enter e Press the function key New A dialog box appears displaying the name of the data see Figure 41 The name of the dat
75. Change Log Change Log Transactions Type of change 2 7 chg attr EIO EIO_USER_SIGNAL I 25 Type DI gt DO add inst EIO EIO_USER_SIGNAL I 33 del inst EIO EIO_USER_SIGNAL I 33 load par FILE eio_ext cfg restart save par FILE EIO CFG OK Figure 2 The Change Log dialog box The following identification tags are used chg attr Shows the parameter that has been changed and how it was changed addinst Shows that a new parameter has been added del inst Shows that a parameter has been deleted load par Shows that new parameters have been loaded save par Shows that parameters have been saved restart Shows that the robot has been restarted 1 6 Checking Parameters When you have changed a parameter it is a sensible idea to check the change before restarting in order to avoid problems when restarting In the current version the Manipulator area can be checked e Select the area to be checked in Topics only Manipulator can currently be checked e Select File Check Parameters and the check will start When the check is finished a report will be made showing that either there was an error or the change of the parameter was done correctly The error will be reported via the usual error log See chapter 14 Service User s Guide 12 5 System Parameters 2 Saving and Loading Parameters 12 6 2 1 Saving parameters to diskette or some other mass storage device The system parameter
76. Check 1 Check the InterBus S configuration according to above error code 71114 Invalid IP address DescriptionReason s is not a valid IP address Check 1 Check the Communication configuration 71115 Invalid subnet mask DescriptionReason s is not a valid subnet mask Check 1 Check the Communication configuration 71116 Disable amp Trust Level 0 DescriptionReason Unit s has been configured disabled with Trust Level set to 0 This is NOT allowed Check 1 Change the configuration 71117 Battery supervision res DescriptionReason The battery capacity d 71118 Battery supervision state DescriptionReason The battery supervision is in wrong State The state is s 71119 IO unit table full DescriptionReason Maximum number of O units of type s exceeded Max d Check 1 Reduce the number of IO units User s Guide BaseWare OS 3 1 System and Error Messages 71120 RAP option not installed DescriptionReason The RAP Communication option has to be installed when configuring RAP or using SCWrite Check 1 Reboot and install the RAP Communication option 71121 RAP start up failed DescriptionReason The initialization of RAP failed Check 1 Check internal log for decription 71122 Incorrect IP address DescriptionReason The address s in protocol s is not a correct IP address Check 1 Change the address 71123 No ma
77. DSQC 350 is the last rack on the RIO Bus Valid values are No Yes Interbus S slave adapter DSQC 351 Unit Type d351 Parameter Description Data Width The data width determines the number of I O signals The valid values are 1 word 16 out 16 1 in 2 words 32 out 32 1 in 3 words 48 out 48 1 in 4 words 64 out 64 1 in Profibus DP slave DSQC 352 Unit Type d352 Parameter Description Master Input Size The master input size determines the number of digital output signals The valid values are 0 word 0 out 1 word 16 out 2 words 32 out 3 words 48 out 4 words 64 out 5 words 80 out 6 words 96 out 7 words 112 out 8 words 128 out Master Output Size The master output size determines the number of digital input signals The valid values are 0 word 0 1 in 1 word 16 1 in 2 words 32 1 in 3 words 48 1 in 4 words 64 1 in 1 Input numbers 33 65 97 or 129 respectively correspond to NAC status LED flashing high at RIO link particularly up i e PLC in programming mode Input numbers 34 66 98 or 130 respectively correspond to NAC status LED steadily lit high at RIO link up 2 Input numbers 17 33 49 or 65 respectively correspond to Interbus S status LED BA steadily lit Bus Active User s Guide 12 11 System Parameters 12 12 5 words 80 1 in 6 words 96 1 in 7 words 112 1 in 8 words 128 1 in Station Address The Profibus node address entered in decim
78. Deg Motion Axes 2 37 5 Deg i C gt 3 180 4 Deg Coord Base 4 Tool tool0 5 Wobj wobj0 6 Joystick lock None 123 Incremental No v gt Robot Manipl Manip2 Trackm Manip3 Figure 24 Specify the unit to be jogged in the Unit field J From this stage onwards the key a can be used to toggle between the external unit that was last chosen and the robot 3 2 Jogging external units axis by axis e Choose the desired axis group using the motion keys see Figure 25 If more than one external unit is used see 3 7 Choosing external units 6 16 User s Guide Jogging Axes 1 2 3 Tas 4 5 6 n A Figure 25 Specify the external axes you want to move by setting the keys as above 3 3 Jogging external units coordinated If an axis is coordinated with the robot defined by the chosen work object the robot also moves when it is jogged The TCP however will not move in relation to the work object If you want to jog the unit uncoordinated choose a work object which is not connected to a coordinated unit e g wobj0 in the field Wobj User s Guide 6 17 Jogging 6 18 User s Guide Inputs and Outputs CONTENTS Page De AG OMOR A E E TT R E OR A E 3 1 1 The Inputs Outputs window s sssesssseseseseesseessrssresressrserssresseserssresseseresressessresreeseeee 3 T2 Choose an VO HS Cs cock cs assahnent date E dees Qusseaienes saci a
79. Edit View Routine Special Program Routines EXERCISE Routines In Module Name T e Yp 1 1 main New Decl Dupl Data gt Test Figure 31 Opening the main file of the training program 4 28 User s Guide Basic Operation Selecting a Program 11 Then press Enter The window in Figure 32 appears File Edit View IPL1 IPL2 Program Instr EXERCISE main 1 4 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 32 The training program appears on the display This is the main routine in the training program It consists of four move instructions The routines consist of different types of instructions such as move instructions wait instructions etc Each instruction is followed by different arguments Arguments can depending on their type be changed or omitted altogether Figure 33 indicates an example of an instruction File Edit View IPL1 IPL2 Program Instr EXERCISE main 1 4 MoveL v300 fine tool0 MoveL v300 fine toold MoveL v300 fine tooll0 MoveL v300 fine tool0 The name of the instruction which moves the robot linearly Copy Pagte OptArg MoaPos Test gt Hides the values of the instruction s Determines the Determines the Specifies which position velocity of the precis
80. Expression reg2 lt _counter_b 1 2 counter_a counter_b regl reg2 reg3 reg4 Text Func Content Cancel OK Figure 18 New data can be inserted into an expression 5 4 Moving and copying instructions e Select the instruction you wish to move or copy To select several instructions choose Edit Mark e Choose Edit Cut move or Edit Copy e Indicate where you wish to add the new instructions e Choose Edit Paste In the Program Instr window copy and paste can also be selected using a function key 6 Running Programs 6 1 Program execution A program can be executed regardless of whether or not it is complete Nonetheless if program execution comes to an incomplete instruction the program is stopped When the program is started the robot checks that all references to data and routines are correct If they are not the fault is indicated and the program is not started This check can also be performed by choosing File Check Program The first fault in the program is then indicated The program is usually started from the first instruction in the main routine but can also be started from an arbitrary routine procedure with no parameters A program that has been stopped is unless otherwise specified always started from the instruction last executed in the program User s Guide 8 21 Programming and Testing 6 2 The Program Test window e Choose View Test When you are in the Program Instr or Progr
81. Figure 5 P Stet characters Expression 789 ABC MNO YZ ve 456 DEF POR lt gt 123 GHI STU 1 0 JCL VWX amp SE A a lt gt Cancel OK Figure 5 The dialog box used for entering text The keys on the numeric keyboard correspond to the selected characters on the display e Select a group of characters by pressing the function key gt or lt e Press the corresponding key on the numeric keyboard If the third group is selected as shown in Figure 5 7 corresponds to M 8 to N 9 to O etc e Move the cursor to the right or left using ArrowLeft lt e Delete the character in front of the cursor by pressing Delete lt e Switch between upper and lower case letters by pressing A a e When you have finished entering text press OK or ArrowRight Starting up 5 10 User s Guide Jogging CONTENTS Page E ESTE A E A R E EAR E 3 ToL The OR SiN WANK OW sosi eiei EE E E E E EE 3 1 2 Reading the current position ssessssseesssessesssesseressseesstessresseesseeesseesssressresseessee 4 1 3 How moving the joystick affects movements ssesesesssesssseeesseesseessersseessseesssees 4 LA Locking Of JOyStick Axes sicissosccsascssscadivatedcaayeiesatsssedededa nn iiiki si 5 13 Metion SUpervisiOn 3 acc 2ki nied eal oni bene Seas EAEN 5 2 Jogeing the ROO s daiacieticintescentctetaadicarceaists soceaisuss catisca
82. Gives a quicker stop and some devi ation from the programmed path A program cannot be started when this signal is high Stops program execution Gives an even quicker stop and some more deviation from the programmed path than Quick Stop A program cannot be started when this signal is high Stops program execution after the current instruction has been finished A program cannot be started when this signal is high Stops program execution when the complete program has been executed i e when the last instruction in the main routine has been executed A program cannot be started when this signal is high Performs a system reset restart i e similar to power off on Executes a routine procedure without changing the start pointer Not valid during program execution When the routine has been executed the normal program can be restarted The name of the routine to be executed is also defined in this dialog e g routinel This signal for example can be used to go to a service position When the normal program is started again the robot will move to the point where it was stopped and continue from there Resets the system output signal Error Synchronises an external mechanical unit The unit to be synchronised is also defined in this dialog e g orbitl One sig nal is required for each unit S4 only Loads a program from diskette or other mass storage device The program is then started from the beginning The pro
83. Manual The Product Manual describes how to install the robot as well as maintenance procedures and troubleshooting If you just wish to be able to start programs run the robot with the joystick load pro grams from diskette etc it is not necessary to read Chapters 14 16 in this manual User s Guide 4 3 Introduction Basic Operation 4 4 User s Guide Basic Operation Safety 2 Safety Operational procedures during training or at any other time must be carried out safely Entering the safeguarded space around the robot may cause severe injury and should be avoided whenever possible However if this is necessary then only authorised personnel may enter the area The existing safety regulations must always be taken into consideration The safety regulations are specified in the chapters on safety in the User s Guide and in relevant plant documentation if any User s Guide 4 5 Safety Basic Operation 4 6 User s Guide Basic Operation System Overview 3 System Overview 3 1 General A robot is made up of two principal parts wun z vel i N MUIN i i Controller Manipulator Figure 1 The controller and manipulator are connected by two cables You can communicate with the robot using a teach pendant and or an operator s panel located on the controller see Figure 2 Figure 2 The teach pendant and the operator s panel User s Guide 4 7 System Overview B
84. RAISE instruction but was not handled by any ERROR clause 40230 Execution error Task 16s Unhandled non fatal runtime error Check A non fatal runtime error has occurred but was not handled by any ERROR clause 40241 Value error Task 16s Array dimension number G out of range 1 i Check The value of the DimNo parameter of the Dim function must be an integer value in the specified range 16 63 System and Error Messages 40242 Type error Task 16s Data is not an array Check The DatObj parameter of the Dim function must be an array 40243 Value error Task 16s Unknown interrupt number Check Check that the specified interrupt variable has been initialized by CONNECT and that the interrupt has been defined using the ISignalDI or other interrupt definition instruction 40244 Value error Object 16s is of non value type Check Use expression or data object of value or semivalue type 40245 Parameter error Parameters in 16s and 16s is not matching late binding Check Make sure that all procedures that are called from the same late binding node have matching parameters I e they should be matching concerning base type mode and required optional parameters 40251 Name error Task 16s Ambiguous symbol name 16s Check Installed objects must have names that are unique Rename the object or change the conflicting name 16 64
85. Risks Related to End Effectors ssccssssccssssccssssccssscscsssssssssssssssscsscssssessees 10 cL GSPN DCT ose ee gasses oe ae E SAS a en Et a 10 8 2 TOOIS WOrKPleCes cacssicnaais acdedazs se ceadesavensanasedaaraedshaa O ERE a R A RSA ESTEI anes 11 9 3 Preumationnydraulie Systems innir e e E E TEE 11 9 Risks during Operation Disturbances sccsssccssssccsssscssssccssseccsssescssssscssscssesssscoess 11 10 Risks during Installation and Service ssccsssscssssccssssccssssccssssscssssssssssscssssscssssecs 11 11 Risks Associated with Live Electric Parts ccsccsssscssssscscscesssscscsecscsesssscssscsees 12 12 Emergency Release of Mechanical Arm ccssccssssscssssccssssccssssscssssssssscscsscsscsessssees 13 13 Limitation OF Lea DULG oe sscccaciendudicoessscvcenuveaneceonsscduncseaeadinndudcsueahcvendeuvenasdesacnestexteteaneswence 13 14 Related Information sisissitsssieisscasiteis sixsvsnshonssevasbeicsbabscsaniaissndtndseiusensatuasebussessetsassuiassentoes 13 User s Guide 3 1 Safety 3 2 User s Guide Safety Safety 1 General This information on safety covers functions that have to do with the operation of the industrial robot The information does not cover how to design install and operate a complete system nor does it cover all peripheral equipment which can influence the safety of the total system To protect personnel the complete system has to be designed and instal
86. Routine 6 Call Service Routine 7 Go to selected position 8 Simulate Command Used to Move Cursor to PP start from the latest stopped instruction see page 8 25 Move PP to Cursor start from the selected instruction see page 8 25 Move PP to Main start from the main routine see page 8 25 Move PP to Routine start from any routine see page 8 25 Call Routine start from any routine without loosing context see page 8 26 Call Service Routine execute configured service routine without loosing context see page 8 27 Go to selected position go to a selected position Simulate allow program execution in MOTORS OFF mode User s Guide 18 17 The Program Window Quick Reference 3 8 Window Program Modules File Edit View Module Program Modules WELDPIPE Name Type 2 4 Cadpositions Program Module Modules Mainmodule Program Module System1 System Module System2 System Module New Decl Data gt Create a new module View program data Change the declaration 3 8 1 Menu Module Module 1 Data 2 Module List Command Used to Data view program data Module List view the complete module in a list see page 8 59 18 18 User s Guide Quick Reference The Production Window 4 The Production Window 4 1 Window Production File Edit View Production Info CAR_LIN1 Routine main Status
87. S SafetyOpKey parameter 12 37 SafetyRunChain parameter 12 37 save module 8 58 parameters 12 6 program 8 28 Save All As parameters 12 6 Save As module 8 59 parameters 12 6 Service window 14 7 Save Module 8 58 Save Module As 8 59 Save Program 8 28 Save Program As 8 28 Screen Viewer 15 15 Screen Viewer Window 15 15 Search 8 37 select several instructions 8 30 Selected Routine 8 12 service window 14 3 Set 9 7 SetAO 9 7 SetDO 9 7 SetGO 9 7 Show Change Log 12 5 Show IPL 8 15 User s Guide signal define 12 12 signal values changing manually 7 6 Simulate wait 8 27 Single Type 12 66 speed correction 8 22 Start from Beginning 11 7 start program 11 6 starting program execution 8 24 start up 5 3 18 21 stationary tool jogging 6 13 stopping program execution 8 25 11 7 storage of program 13 3 store module 8 58 program 8 28 string 8 18 subroutine 8 5 8 8 call 9 10 System Inputs define 12 22 system module 8 6 System Outputs define 12 24 system parameters 12 3 change log 12 5 load 12 7 save 12 6 T TCP 10 28 Teach Pendant 4 10 parameters 12 45 teach pendant 5 7 TEST change structure 8 35 Test 8 22 Testing mode 4 9 text 5 9 time setting 14 3 tool change 10 29 10 31 define 10 28 tool coordinate system jogging 6 7 tool reorientation 6 9 20 5 Transmission 12 57 12 66 trap routine 8 9 trimming external axes 12 70 12 71 typographic conventions 2 4 U Unmark 8 30 Update
88. Sensor error Camera alarm Check Some error has been detected in the camera Run Camcheck to test if the camera is OK 40644 Sensor error Temperature alarm Check The camera is overheated it needs more cooling air or water 40645 Sensor error Value out of range Check The value of the data sent to the sensor is out of range 40646 Sensor error Camera check failed Check The CAMCHECK function failed The camera is broken Send it for repair 40647 Sensor error Communication time out Check Increase the time out time and check the connections to the sensor 40648 Search error Not possible to do StorePath while searching on basic path level Check If using program with robot movement in TRAP then such interrupt must be deactivated during any searching E g Sleep SearchL Watch 16 72 40649 Path limit error s already done Check Instruction s must first be executed before a new s can be done 40650 Wrong param combination Optional parameters and switches are not used in a correct combination Check No optional parameters and no switch keeps the old coordinate system The switch Old has the same function RefPos or RefNum has to be defined with Short Fwd or Bwd 40651 Use numeric input Use numeric input for the position instead of a robtarget Check The position can not be defined with a robtarget for robot axes Use the optional parameter for numer
89. Store If set to YES the digital outputs will be stored at a power failure and restored when the system is powered up again It should be noted that the value is connected to a logical sig nal If more than one logical signal is connected to the same physical signal an unexpected value may be obtained In such cases this parameter should be set to NO 3 5 Defining cross connections A digital input or output signal can be logically connected to one or several digital input or output signals This means that a cross connected signal will automatically be changed when the activation signal is changed See also RAPID Reference Manual Motion and I O Principles e If the signal has not already been defined then define its name in the normal way See Defining input and output signals on page 12 e Choose Topics IO Signals e Choose Types Cross Connections All the defined cross connections will be displayed see Figure 9 User s Guide 12 15 System Parameters 12 16 File Edit Topics Types System Parameters IO Signals Cross Connections From To 1 4 dil do5 dos do5 dos dil do9 di25 Add Figure 9 An output signal can be logically connected to an input signal e Select the cross connection to be changed and press Enter or add a new one by pressing Add e Define the activation From signal and the corresponding cross connected To signal e Press OK to con
90. Use max 16 characters to specify the name of a mechanical coordinated unit 40610 Argument error Argument WObj specifies a mechanical unit name which is not activated or unknown in the system Check The mechanical unit name defined in WObj must correspond to the name earlier defined in the system parameters and must be activated 40611 Execution error Not allowed to step backwards with this move instruction Check Step backwards to a position defined with another tool or work object could result in fualty path 40612 Argument error No argument programmed for the name of the output signal Check Possible to set one position fix IO such as digital group of digitals or analog output signal during the robot movement 40613 Argument error Optional argument s can only be combined with output signal argument s 40614 Argument error Argument s is not O or 1 Check Digital output signals can only be set to Oor 1 16 70 40615 Argument error Argument s is not an integer value Check Digital group of output signals process identity or process selector can only have an integer value 40616 Argument error Argument s is outside allowed limits Check Used group of digital output signals can only be set within 0 to s according configuration in the system parameters 40617 Argument error Argument s is outside allowed limits Check Used analog output signals can only be
91. User s Guide 4 21 Jogging the Robot Using the Joystick Basic Operation When linear type motion is selected the robot will move as shown in Figure 16 Y Figure 16 X Y Z form the robot s coordinate system The point that will move linearly along the axes of the coordinate system above is called the Tool Centre Point TCP 0 It is located at the front of the upper arm in the centre of the robot s face plate see Figure 17 Tool Centre Point 0 Figure 17 The centre of the face plate is called TCP 0 3 Push the enabling device halfway in to switch the MOTORS ON 4 Now jog the robot using the joystick Standing in front of the robot the TCP 0 will depending on how you move the joystick move linearly along the X Y and Z axes see Figure 18 Figure 18 Robot movements with different joystick deflections Try jogging the robot in the directions corresponding to X Y and Z above You can also combine the various movements of the joystick and move in several directions simultaneously Note that the speed of the robot depends on how much you move the joystick The larger deflection the faster the robot moves 4 22 User s Guide Basic Operation Jogging the Robot Using the Joystick 6 2 Fine positioning 1 Press the Jogging window key see Figure 19 Figure 19 The Jogging window key A window like the one in Figure 20 will appear
92. a new tool A tool should normally be placed in the system module User In that way it will be common to all programs which means that if a TCP is modified all programs will automatically be affected The tool can then also be used for jogging when there is no program in the program memory e Open the Program Data Types window by choosing View Data Types e Select the type tooldata and press Enter e Create the new tool using one of the following alternatives alt 1 Press the function key New The tool s TCP and orientation will then be the same as the robot s mounting flange alt 2 Select an existing tool and press the function key Dupl The tool s TCP and orientation will then be the same as the one duplicated A window appears displaying the name of the data e If you want to change the name press Enter and specify a new name e Press the function key Decl A dialog box appears displaying the basic tooldata declaration e If you want to save the data in another module select the field In Module and press Enter Specify the name of the module in which the data is to be saved e Press OK to confirm Note Do not change the type of the tool This must always be of the persistent type User s Guide Calibration 7 2 Manually updating the TCP and weight of a tool e Open the Program Data Types window by choosing View Data Types e Select the t
93. a work object User s Guide 10 37 Calibration 10 38 8 6 Using the robot to change the work object e Choose View Data Types e Select the type wobjdata and press Enter e Select the work object to be defined or create a new one see Creating a new work object on page 36 e Choose Special Define Coord A dialog box appears displaying the points defined by the method that was used see Figure 34 Sea Work Object Coordinates Definition Before starting make sure gt J WObj wobj2 that the tool displayed is 3 TOO stoori the one you want to use User Method 3 points Object Method 3 points Points Status 2 6 User X1 Modified User X2 User Y1 E Object X1 Desc ModPos Cancel OK Figure 34 The robot can be used to define the position of the work object The status can be defined as follows Status Meaning No position defined Modified Position modified To record Measuring Points for the user coordinate system Note If the work object is defined using a movable user coordinate system the user coordinate system is defined in the Service window See Coordinated external axes on page 16 e Select the first measuring point User X1 e Jog the robot as close as possible to a point on the x axis e Modify the position by pressing the function key ModPos e Select the measuring point User X2 e Jog the robot as close as possible to a point on the x axis de
94. all mechanical units in the list 20050 Not allowed command Not allowed in this operating mode 20051 Not allowed command Not allowed when client not in control of the resource program motion 20052 Not allowed command Not allowed in this cabinet state 20053 Not allowed command Not allowed in this manipulator state 20054 Not allowed command Not allowed when program is executing 20060 Not allowed command Not allowed in Auto mode 20061 Not allowed command Not allowed when changing to Auto mode 20062 Not allowed command Not allowed in Manual mode 20063 Not allowed command Not allowed in Manual full speed mode 20064 Not allowed command Not allowed when changing to Manual full speed mode 20070 Not allowed command Not allowed in Motors On state 16 28 20071 Not allowed command Not allowed while changing to Motors On state 20072 Not allowed command Not allowed in Motors Off state 20073 Not allowed command Not allowed while changing to Motors Off state 20074 Not allowed command Not allowed in Guard Stop state 20075 Not allowed command Not allowed in Emergency Stop state Check Em stop reset is required Press the panel button 20076 Not allowed command Not allowed in System Failure state Check Fatal non recoverable system error Warm start is required Switch the mains switch off and on again if the soft restart command is ignored or not possible to reach
95. and Point 3 To calculate the user frame e Press OK to calculate the user frame for the selected mechanical unit User s Guide Calibration When the calculation is finished a dialog like the one in Figure 13 will appear EEE Rot Single User Frame Calc Result Calculation Log ROT_SINGLE 1 10 Method n points n 3 Mean error 1 12 Max error 2 31 Cartesian X 7 08 Cartesian Y 35 55 Cartesian Z 97 00 File Cancel OK Figure 13 The result of a user frame calculation for a rotating single The calculation log shows the user frame expressed in the world coordinate system when the mechanical unit is in its calibration position Field Unit List contents Method Mean error Max error Cartesian X Cartesian Y Cartesian Z Quaternion 1 4 Description The name of the mechanical unit for which the definition of user frame is to be done Description Displays the selected calibration method The accuracy of the robot positioning against the reference point The maximum error for one positioning The x coordinate for the user frame The y coordinate for the user frame The z coordinate for the user frame Orientation components for the user frame The calculation result can be saved in a separate file for later use in a PC e Press the function key File e Specify a name and a location where to save the result e Choose OK to confirm the save If the estimated erro
96. argument expression is just a data or parameter reference 40005 Argument error Task 16s Argument for INOUT parameter 16s is not variable or persistent reference or is read only Check Make sure the argument is just a variable persistent variable parameter or persistent parameter reference and it is writeable Do not use around the argument 40006 Argument error Task 16s Missing optional argument value for parameter 16s Check Only switch parameters may be specified by name only Optional parameters of other types must be assigned a value Add a value 16 49 System and Error Messages 40007 Argument error Task 16s Optional argument 16s at wrong place in argument list Check Check that the arguments are specified in the same order as the parameters for the routine being called 40008 Argument error Task 16s Reference to optional parameter 16s in required argument Check An argument corresponding to an optional parameter must be specified with a leading character Change the required argument into an optional 40009 Argument error Task 16s Reference to required parameter 16s in conditional argument value Check A conditional value for an optional parameter must refer an optional parameter in the calling routine Change the conditional value 40010 Argument error Task 16s Reference to required parameter 16s in optional argument
97. as PHAN Ces 5 6 Preferences the menu File to 7 8 Check Program or to create a new Close Program Program Figure 27 The File menu when there is no program in the robot s internal memory 4 26 User s Guide Basic Operation Selecting a Program The menu that now appears on your display is called a pull down menu All com mands that can be chosen from the File menu are listed here commands that cannot be chosen are indicated by parentheses The other menu keys work in the same way From now on we will write File Open File Save etc The name on the left of the colon is the name of the menu and the name on the right stands for the command you should choose The first function in the pull down menu is always highlighted when you press the menu key You can move the cursor within the menu using the arrow keys on the teach pendant see Figure 28 When you have selected the command you want to choose press Enter You can also use the numeric keyboard to choose a command to do this enter the number in front of the command Up arrow a CILe L gt UJ Down arrow Figure 28 Navigation keys Up arrow and Down arrow Three dots following the command means that a dialog box will appear when that command is chosen To remove a pull down menu press the menu key with which you opened it 5 After selecting Open press Enter see Figure 29 This means that the Open
98. board 31146 Noise error tpu channel Check 1 Check communication parameters 2 Replace robot computer board 31203 Floppy Disk Error Bad floppy disk or not formatted Check 1 Repeat attempt 2 Change disk 31206 Floppy Disk Error Bad floppy disk or internal error Check 1 Check the floppy drive 2 Change disk 3 Restart the system 31207 Floppy Disk Error No floppy disk or disk not ready Check 1 Repeat attempt 31210 Floppy Disk Error Invalid format Check 1 Change disk 31211 Floppy Disk Error Data transfer error to from floppy Check 1 Repeat attempt 2 Change disk 3 Restart the system 31214 Floppy Disk Error Data transfer was interrupted Check 1 Repeat attempt 2 Restart the system 16 36 31215 Floppy Disk Error Internal command invalid Check 1 Repeat attempt 2 Restart the system 31216 Floppy Disk Error Floppy disk was moved during tranfer Check 1 Repeat attempt 2 Restart the system 31217 Floppy Disk Error Bad floppy disk or floppy device Check 1 Repeat attempt 2 Change Disk 3 Restart the system 31219 Floppy Disk Error Floppy device not ready Check 1 Repeat attempt 2 Restart the system 31220 Floppy Disk Error Bad floppy disk or internal error Check 1 Repeat attempt 2 Change Disk 3 Restart the system 31221 Floppy Disk Error Data error Check 1 Repeat attempt 2 Change Disk 3 Restart the system 31222 Flo
99. c c ccsdcceesccelesshes sassacesscasenee seendcasaastebes seaecnceacs 8 25 6 8 Simulating wait CONMHONS lt 5ccissisasconsavsscssdgreceeial asceaseaaeteaisaconteneaseiosases 8 27 7 Saving and Printing Programs vscsiesecciscssiccerscewedececcecveasesnedsnsninnetaceesneenssesevaveees 8 28 7 1 Saving the program on diskette or some other type of mass memory 8 28 7 2 Printing a program from the robot sssessessesssesesseeessesseessersseresseeesseesseesse 8 29 7 3 Printing a program using a PC sssessesssnssesssesesseessstessressersseresseessseessresseessee 8 29 8 Changing the Program seesseecsosecoosecoecococcocccoosecoecoscosococcosecoosesoessscosssscsossesssess 8 29 8 1 Selecting an instruction or an argument esssessesseeereeeerstesresressersresresressese 8 30 8 2 Modifying the position in a positioning instruction eeeeseeeeseeereereeserereee 8 31 8 3 Tuning position during program execution esesseesseeeesserssressersseessseesseee 8 31 8 4 Changing an argument ii vscvecisessvaisisvscvessisvgeadoassacceva lesveaensesnaaeusdacedenteoweavesesens 8 33 8 5 Adding optional arguments sseseseeeeeseseeseeerseesseteserereretsseesstesseesseesseseesees 8 34 8 6 Changing the structure of an IF FOR or TEST instruction 0 eee 8 35 8 7 Changing the name or declaration of a routine eesseseeeseseeereserererrrsreeeee 8 35 8 8 Deleting an instruction or an argument essseesssessessseeesee
100. can be used to damp oscillations of the axis due to mechanical resonance This parameter is only available in the Trq configuration For most applications it is not necessary to adjust Df If however the torque_ref signal is oscillatory due to mechanical resonance then the performance of the axis can be improved by adjusting Df To do this measure the distance between resonance peaks in mm on the plot of the torque_ref signal A rough estimate of Df can be obtained by dividing this value by the chart recorder speed in mm sec f chart recorder speed distance between resonance peaks Df should be in the range 3 to 25 To tune Df program short back and forth motions of the axis at maximum speed The axis should not be allowed to reach full speed before deceleration Use the TUNE_DF argument of the TuneServo command to adjust Df and examine the torque_ref signal Adjust Df until the oscillations in the torque_ref signal are damped out User s Guide System Parameters 7 16 Activate forced gain control for an external axis When activating forced gain control for an external axis two Types under Manipulator must be considered In Lag control master 0 you can decide which axes should have forced gain control and in Supervision you can decide which axes should affect forced gain control All the axes that affect forced gain control must be within a certain positional range from the end point before the forced gain control is enabled Th
101. cannot be set PP cannot be set to routine s because it resides in a module which has NOSTEPIN as module attribute Check Copy the routine s to another module or change the module attribute 60017 PGM_TELLBACK code d Check No more information available 60018 RAPID syntax error The program cannot be loaded because of syntactical error s Check A RAPID syntax check program for the PC or QuickTeach can be used to detect the error s The file PBMCPL1 LOG on the internal RAM disk contains information about the error s 60019 Data input error The component s in data type s is not correct The limits are s Check Check data and enter the correct value 60020 PP cannot be set PP cannot be set to routine s because it is defined as a trap routine Check Change the definition for the routine s to Procedure 16 88 60021 Cannot show items The number of selected items exceeds the current memory limit specified for this configuration The items can thus not be shown Check Reduce the number of data or change the configuration to a memory board with more memory 60022 Cannot show all items Only d variables out of d will be listed All variables cannot be shown because the current memory limit specified for this configuration will be exceeded Check Reduce the number of data or change the configuration to a memory boa
102. control The positions are expressed in radians for the motor Keep Forced off pos limit 0 unless the forced factors cause problems such as noise from the motors when in position AN Do not change supervision for the robot axes This can reduce the service life of the robot and impair its performance User s Guide 12 75 System Parameters 12 76 7 17 Activate notch filter for an external axis This is used only in arc welding applications when a variation in external axis speed affects the welding process This problem sometimes occurs when both coordinated interpolation and weaving are used The frequency of the speed variation is typically 2 times the weaving frequency The notch filter will prevent the external axis from oscillating at the weave motion frequency There are two ways of using the notch filter One way is to lock the notch filter to one specific frequency specified in the parameter Notch filter frequency The other way is to activate Notch auto mode which means that the notch filter will automatically adjust to the current weave frequency A notch filter should not be used together with Rapid Weave In Notch auto mode this is handled automatically and the notch filter will work as if there was no weaving at all To activate Notch auto mode the system needs to be booted with the Service option e Choose Topics Manipulator e Choose Types Lag control master 0 e Select the lag control master corresponding to t
103. coordinate system The methods are the same as for a TCP mounted on the robot However in this case the reference tip is mounted on the robot and the robot is moved so as to bring the tip to the stationary tool TCP The tip must be defined and activated as a tool before the def inition of the stationary tool may be done e Define and activate the tool which should be used as a pointing tip and which is mounted on the robot e Now the same methods for defining the stationary tool may be used as described in Manually updating the TCP and weight of a tool on page 29 and Using the robot to change the TCP and orientation of a tool on page 31 Use the robot mounted tip to point out the stationary TCP with four approach points and if needed the z and x directions of the axes It is possible to use the same positioning for all four TCP approach points to perform a faster frame definition However it is recommended to point out the stationary TCP with different orientations to obtain a reliable statistical result The point that is used to approach the stationary TCP must be the active TCP hold by the robot Note If the stationary tool is to be used with coordinated track motion the coordina tion must be active during the calibration of the stationary tool User s Guide Calibration 8 Work Objects and Program Displacements 8 1 General All programmed positions are related to a program displacement frame which in turn is related
104. definition incorrect use load identification If external forces use RAPID command or system parameters to raise supervision level 50205 Data logger error s Check Solution 50206 Probe warning Probe buffer is full 50207 Add intermediate point Add intermediate point not coordinated to external pos mechanical unit when changing conveyor Check Create an intermediate point then change the conveyor 50208 Missing function Friction Compensation can not be activated for joint s Check Install the option Advanced Motion 50209 Kinematic limitation No accepted solution found Residual ld deg in orientation ld mm in x d mm in y ld mm in zZ Check Insert an intermediary point Check singularity Increase position and orient tolerance Use MoveAbsJ Check working range 16 86 50210 Load identification error Check Possible problem Load identification not allowed for this robot Configuraion angle is too small 50211 External Drive error External controlled drives can not be used without the option External Drive 50212 General kinematics General kinematics can not be used without the option gt General Kinematics 50213 Frame rotation error Possibly due to unnormalized quaternion or position out of bounds Check Check the normalization of input quaternions or magnitude of input positions 50214 Configuration error of work area Possibly the
105. e Press Enter e Select the desired parameters Single jog dir to be changed Selecting the default type restores factory default jog directions Do not perform the Restart requested here e Repeat for all singles e Press OK to confirm e Choose Types 2 Single jog e Select the desired parameter type e Edit the elements e Press OK to confirm e Perform a Restart to activate the modifications to the joystick directions When joystick directions for both robots and single axes are to be modified it is not necessary to perform the restart until all the modifications have been made Single axis joint jogging Parameters Description Joint The attachment of a single axis of a mechanical unit to a joystick deflection 1 gives attachment to downways joystick deflection 2 gives attachment to rotating joystick deflection 3 gives attachment to sideways joystick deflection 7 21 Defining kinematic parameters for general kinematics It is possible to use general kinematics for both master robot and external robots Def inition is not possible via the teach pendant PC editing of the MOC cfg file is neces sary Denavit Hartenberg notation according to John J Craig Introduction to Robotics Mechanics amp Control Addison Wesley 1986 is used MASTER ROBOT User s Guide 12 81 System Parameters 12 82 The following data needs to be defined e Under ROBOT_TYPE pos_tol_x pos_tol_y pos_t
106. exchange Welddata Unit 117013 Welding equipment error Welddata Unit CAN controller for external bus is in WARNING state Check Change data several times or reset welding equipment with power switch If the error do not disappear check bus connections and or exchange Welddata Unit 117014 Welding equipment error Welddata Unit CAN controller for internal bus is in BUS OFF state Check Reset welding equipment with power switch If the error do not disappear check bus connections and or exchange Welddata Unit 117015 Welding equipment error Welddata Unit has detected that a received internal CAN message was lost Overwritten by a later message Check Reset welding equipment with power switch 117016 Welding equipment error Welddata Unit has detected that a received external CAN message was lost Overwritten by a later message Check Reset welding equipment with power switch 16 105 System and Error Messages 117017 Welding equipment error Welddata Unit lost contact with Wirefeed Unit Check Check connection cable between Weld data Unit and wirefeed control board check power supply to wirefeed control board 117018 Welding equipment error Welddata Unit has lost contact with Olivia Unit Check Check connection cable between Welddata Unit and Olivia unit check power supply to Olivia Unit 117019 Welding equipment error Non volatile RAM data value failure detected in Welddata Unit at p
107. execution mode is changed from continuous to step by step or cycle the robot will stop automatically after it has completed the instruction or the cycle 6 7 Where will the program start How do you recognise the program pointer The program pointer shows how far the program has run and is marked with gt in front of the instruction An instruction that has been fully executed is marked with an x but is only shown during instruction by instruction execution If the cursor is positioned at this instruction the program starts from the program pointer gt gt See the example below In all other cases the cursor will define the instruction that will be executed when you press Start Example IF reg1 5 THEN x reg2 5 The last instruction executed ELSE reg2 8 ENDIF gt Set dol The next instruction to be executed User s Guide 8 25 Programming and Testing 8 26 If the cursor is not located on the last instruction executed then when you press Start an alert box will be displayed because the program flow has been changed Select whether you wish to start from the program pointer PP or the cursor using the arrow keys Cursor does not coincide with Program Pointer PP Start program from PP Cursor Cancel e Press Enter To move the cursor to the program pointer e Choose Special Move cursor to PP To move the program pointer to the cursor e Choose Special Move PP to curs
108. files and catalogues e Give the file to be moved a new name by selecting To and press Enter If you do not specify a new name the file directory that is moved will retain the same name e Specify the destination unit first part of At field by pressing the Unit function key If you do not specify a unit the same unit that was used originally will be used e Specify the destination directory latter part of At field by selecting the lower part of the window Select the desired directory and press Enter e Choose Move to start moving 3 6 Printing files e Select the file to be printed e Choose File Print File e Choose OK to start printing 4 Formatting a Diskette NB The previous contents on the diskette will be erased when formatting e Choose Option Format A confirmation dialog will be displayed e If desired rename the diskette and press Enter J e Choose OK to start formatting User s Guide 13 7 File Manager 13 8 User s Guide Service CONTENTS Page 1 The Service Wim OW si sssccsscssccessscsccesacaceGasesenesneassscedacaesastebes casas scucdeescncegannocceeheatescgineseess 2 Changing the Current Date and Time csssccssssscssssccssssccssssscssssccssssssssssssssssssens 3 i E EEE S T E T AE O 4 Sal Whatisa 10g 2026 aana a ai a E A A A A Re 4 3 2 What types Of logs are There ix ssicsscisiecaissasvasecssudens caseaa sade sedatives intii
109. for power failure restore The table for power fail is full Check 1 Increase the table size in startup file 2 Remove some other signal from restore list 71058 No contact with I O unit DescriptionReason No contact with I O unit s on bus s Check 1 Check the addresses on all I O units connected to the bus 2 Change the address 71059 Error config Can node DescriptionReason Error when configuring Can node connected at node address d Check 1 Correct the configuration for the Can node at given address 71061 I O bus error DescriptionReason An abnormal rate of errors on bus s has been detected Check 1 Check the bus 2 Restart System 16 93 System and Error Messages 71072 No save set on signal DescriptionReason Signal s has not Set the Store attribute to YES Check 1 Set the Store attribute 71073 Error on I O Bus DescriptionReason An abnormal rate of errors on the s Bus has been detected The connector for External CAN I O has been switched off Check 1 Check bus terminators 2 Check I O bus for short circuit 3 Restart system 71074 Config out of range DescriptionReason The IBS starting quarter and rack size 1s out of range for board s Check 1 For starting quarter 1 rack size must be less than 5 71076 Comm error from rtp1 DescriptionReason No response from the serial line Check 1 Check the device or connection 71077 Co
110. have selected the function Set the dialog box in Figure 69 appears eEO wT Instruction Argument Set lt EXP gt Signal 1 11 New dol d02 d03 d04 d05 d06 d07 dos d09 d010 do11 Next Func More Cancel OK Figure 69 Dialog box for selecting a digital output signal 4 Select do4 in the list Press OK The window in Figure 70 appears File Edit View IPL1 IPL2 Program Instr XXXXX main I O 4 7 MoveL v300 z10 tool0 1 Invertbo MoveL v300 z10 tool0 2 PulseDO MoveL v300 fine tool0 3 Reset Set do4 4 Set Moven ee v300 fine tool0 5 SetAO WaitTime 3 MoveL v300 fine tool0 6 SetDO 7 SetGO 8 WaitDI Copy Paste OptArg ModPos Test gt Figure 70 The Set do4 instruction has been entered into the program 4 58 User s Guide Basic Operation I O Signals 5 Remove the pick list of instructions by pressing Edit Hide IPL The window in Figure 71 will then appear File Edit View IPL1 IPL2 Program Instr XXXXX main 4 7 MoveL v300 z10 tool0 MoveL v300 z10 tool0 MoveL v300 fine tool0 Set do4 MoveL v300 fine tool0 WaitTime 3 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 71 The Program Instruction window 6 Test run the program using the Test function one instruction at a time so that the Set do4 instruction can be read by
111. is displayed e Choose the directory in which the module is to be saved Move up or down in the directory by choosing either up or the desired directory down and press Enter Create a new directory by pressing New Dir e Press Enter when the field Name is selected e Specify the new name using the numeric keyboard in the dialog box that appears Press OK when you have finished entering the new name e Choose OK to confirm the save 13 12 Calling up the complete module list e Choose View Modules e Select the desired module e Choose Module Module List The complete module is displayed including its data declarations and routines It cannot however be changed e Exit the module list by pressing OK User s Guide 8 59 Programming and Testing 14 Preferences 14 1 Defining the Most Common instruction pick list You can define the contents of the Most Common instruction pick list to obtain a pick list of the instructions you use most e Choose File Preferences e Select for example Most Common SetUp 1 e Press Enter lt All instructions and procedures are displayed Those included in the pick list are marked with an x to the left of their names see Figure 51 ae es Most Common SetUp 1 7 40 x AccSet ClkReset ClkStart ClkStop Close X Compact IF ConfJ ConfL Result gt Excl Cancel OK Figure 51 You spec
112. is unacceptable 1 Verify that correct TCP is used 2 Try more than 3 ref points 3 Be careful when positioning robot to ref points 50145 Kinematic limitation Kinematic limitation no solution found 1 Long segment 2 Position close to singularity 3 Joint 1 2 or 3 out of range 4 Position outside reach Check 1 Insert an intermediary point to reduce the length of the segment 2 Use MoveAbsJ 3 4 Check working range 50146 Restart limitation Corner path executed as a stop point Power fail restart not possible near the stop point Check Use finepoint in the Move instr before RestoPath ActUnit Wait or Stop instr to make power fail restart possible 50147 Power fail restart failed Re creation of the path failed Check Move the start point and start anew movement 16 81 System and Error Messages 50151 MOC_MAILBOX1_ ERROR The axis computer driver failed to generate a new mailbox interrupt since the previous interrupt has not been serviced properly Check Reload system Replace robot computer board 50152 MOC_MAILBOX2_ERROR The axis computer driver failed to generate a new mailbox 2 interrupt since the previous interrupt has not been serviced properly Check Reload system Replace robot computer board 50153 Command not allowed The given instruction or command was not allowed since the robot program was executing in a hold state s d d Check Modify p
113. keys Le to reorientate the tool The tool is reorientated about the axes of the coordinate system that was chosen The TCP of the chosen tool will not move see Figure 12 Figure 12 Reorientation about the tool coordinate system s axes 2 4 Aligning a tool along a coordinate axis The Z direction of a tool can be aligned along a coordinate axis of a chosen coordinate system The angle between the tool s Z direction and the coordinate axes determines which coordinate axis the tool should be aligned along the axis closest to the tool s Z direction will be used see Figure 13 User s Guide 6 9 Jogging Zs TCP X Y X Y Figure 13 The tool is aligned along the Z axis Adjust the direction of the tool manually so that it is close to the desired direction e Choose Special Align A dialog box appears displaying the coordinate system used for alignment see Figure 14 Align The alignment is started by moving the joystick The tool will be aligned along a coordinate axis of World Coord World World Base Wobj OK Figure 14 The dialog box for aligning the tool If you want to change the coordinate system press any of the function keys World Base or Wobj e To start the alignment press the enabling device and move the joystick The joystick is used to adjust the speed The robot will automatically stop as soon as it reaches the desired position
114. log on Command 14 7 Update log on Event 14 7 User screen 15 15 user screen package 15 15 User Signals parameters 12 12 Vv variable 8 45 W wait a specific time 9 10 for an input 9 8 WaitDI 9 8 WaitTime 9 10 WaitUntil 9 8 warning message 18 22 welcome window 4 15 work object change 10 37 10 38 working space limit 12 54 world coordinate system define 12 61 jogging 6 13 20 6 User s Guide Glossary Argument Automatic mode Component Configuration Constant Corner path Declaration Dialog Dialog box Error handler Expression Fly by point Function Group of signals Interrupt VO Main routine Manual mode Mechanical unit Module Motors On Off Operator s panel Orientation Parameter Persistent Procedure User s Guide Glossary The parts of an instruction that can be changed 1 e everything except the name of the instruction The applicable mode when the operating mode selector is set to One part of a record The position of the robot axes at a particular location Data that can only be changed manually The path generated when passing a fly by point The part of a routine or data that defines its properties Any dialog boxes appearing on the display of the teach pen dant must always be terminated usually by pressing OK or Cancel before they can be exited A separate part of a routine where an error can be taken care of Normal execution can then be restarted au
115. new position with the same orientation as the user frame If you want another orientation use method 3 Method 3 e Activate the coordinated work object suppose it is named co_wobj create three positions e g p1 p2 and p3 p1 should be located at the origin of the shifted object frame p2 on the x axis and p3 in the x y plane e Program and execute the instruction co_wobj oframe DefFrame p1 p2 p3 8 8 How to use different work objects to get different displacements Suppose you have used the work object wobj_use when creating a procedure draw_fig as below MoveL p1 v200 z1 tool1 WObj wobj_use MoveL p2 v200 z1 tool1 WObj wobj_use MoveL p3 v200 z1 tool1 WObj wobj_use User s Guide Calibration MoveL p4 v200 z1 tool1 WObj wobj_use MoveL p5 v200 z1 tool1 WObj wobj_use wobj_use Pl P2 y P y Pa P3 X Now you want it to be performed displaced corresponding to wobj1 wobj2 or wobj3 see below wobj2 wobj1 t sa Suppose that the value of reg is used to control which work object should be used If reg 1 wobj1 should be used if reg 2 wobj2 should be used and if reg 3 wobj3 should be used User s Guide 10 41 Calibration The program below will set wobj_use wobj1 if regl 1 then call the draw_fig pro cedure etc IF regl 1 THEN wobj_use wobj1 draw_fig ENDIF IF reg1 2 THEN wobj_use wobj 2 draw_fig ENDIF IF reg1 31 THE
116. oc joi cos5 sets ca eaccss cass covey caos cecuuabanenncioo co rensonccpasend ipsa atrasite stia int 12 9 3 1 Defining VO Statins tarts tees isco deen tenn a a densa eaes 12 9 3 2 Additional parameters for gateway field bus UMItS eects eters 12 10 3 3 Defining input and output signals 000 0 eee ee eececeeeeeceseeeceeeeecseeeecseeeeneeeesaes 12 12 3 4 Detining signal Oroa ps soxsa cain Sai audatenia ito alee 12 14 3 5 Defining cross connections 5s3c2ssssessadesdessceseaedeasstavadaetangadedvagheodossagaas abantotasedes 12 15 3 6 List all available I O Unit Types s 2s lt ates soaqsscosaseas susedavespaqecs de soseosatevteasaisendoes 12 19 3 7 HO Data Specifications sisstin aii ii aa n i 12 21 3 8 Definin system inputs 5 ee a E E Salle alice TE 12 22 3 9 Defining system OuUlpuUtsscas ccdeis lacs dates ussacaaueseeactguenecad stedtara dees acdeebedetes eaeantas 12 24 310 PLS Communication se aaa ees cs A n kana naan 12 26 4 Topic Communication eeeseoessoesssccsocesocesoocessesssecesocssocssoosesocessccesocesoosssoesssesssose 12 31 4 1 Defining physical channels eeseseeseeseeeseeeeesressesersseessrserssreseseresresseseresresee 12 31 4 2 Defining Transmission Protocol sseseeeseesesseesresressessresressersreseresresseseresresee 12 32 User s Guide 1 7 4 3 Defining Application Protocol cee eeeccecsscecesececeeccececeecseeeesaeeeeteeeeaees 12 34 5 Topic Controller cgcaieiciieis cc cece eee ws ncn cs eee es 12 37
117. occurred The program would not restart after this type of error The pro gram can usually be started but it will start from the beginning The motion supervision function has been triggered The motion supervision function is active An attempt to start the program has been done but this failed due to that the robot was outside the Regain Distance zone i e too far from the programmed path The output is reset by one of the following actions A restart of the program has to succeed the robot must be jogged into the zone first The PP has to be set to Main Several output signals can be assigned the same system status but several system sta tus may not be assigned to the same signal User s Guide 2 Also active for Event Routine execution 12 25 System Parameters To delete a system status e Select the signal to be deleted e Press CX The system status assigned to this signal is then deleted but the signal itself remains defined 3 10 PLC Communication This chapter describes how to control the robot using for example digital signals from a PLC For a definition of the signals see chapter Defining system inputs on page 22 and Defin ing system outputs on page 24 All system inputs are 0 to 1 level sensitive and the pulse length must exceed 50 ms Most system inputs are only permitted in the automatic mode If any interactive unit such as the teach pendant a computer link etc has
118. on the menu command line File Edit View Undo Delete Copy Paste Goto Top Goto Bottom Mark OPWNEF Figure 31 In this example the latest Delete command can be undone 8 36 User s Guide Operations that are possible to undo Programming and Testing Delete Cut Paste are always possible to undo Change Selected is used to change the arguments to an instruction When the operation is ordered either via Edit Change Selected or by pressing Enter pa acopy of the entire selected instruction is made If the operation is to be undone the instruction is replaced by this copy Optional Arguments is used to add or remove arguments to instructions or procedure calls Undo is handled as Change Selected New Instruction is undone by removing the latest inserted instruction Each of these operations clears previous undo buffers E g it will not be possible to Undo a previous delete operation when a new instruction has been inserted When Undo is performed the part of the program that is affected will be shown Limitations Operations that change data values e g ModPos and Edit Value cannot be undone 9 Special Editing Functions 9 1 Search amp replace The search and replace function makes it possible to search for and replace data names in the program It is also possible to search for replace procedure function calls Instruction names can also be changed e g from MoveL
119. or can t be disabled Check The unit name is misspelled not defined or can t be disabled 40708 T O unit is not enabled Task s T O unit 40s was not enabled Check The maximum period of waiting time was too short Increase the waiting time or make a retry User s Guide BaseWare OS 3 1 System and Error Messages 40709 T O unit is not disabled Task s T O unit 40s was not disabled Check The maximum period of waiting time was too short Increase the waiting time or make a retry 40710 Argument error Task 16s Argument error from 16s The argument is expression value is not present or is of the type switch Check Change the parameter 16s toa valid one 40711 Alias type error Task s The data types for the arguments FromSignal and ToSignal must be the same and must be one of signalxx signalai ao signaldi do signalgi go Check Change the type to a valid one 40712 Event routine error Task s Too many event routines the routine s will not be executed Maximum 4 routines could be specified for each event Check Encapslulate the routine in one of the others that are specified for the save event 40713 Alias define error Task s FromSignal must be defined in the io system ToSignal must not be defined in the io system it should just be defined as a variable 16 75 System and Error Messages 40714 Argument error Orientation defini
120. or other object with the specified name is visible from this program position 40093 Instruction error Task 16s Assignment target is read only Check The data to be assigned a value may not be a constant read only variable or read only persistent 40094 Data declaration error Task 16s Persistent declaration not allowed in routine Check Persistents may only be declared at module level Move the persistent declaration from the routine 40095 Instruction error Task 16s RAISE without expression only allowed in error handler Check Add an error number expression to the RAISE instruction 16 58 40096 Instruction error Task 16s RETRY only allowed in error handler Check The RETRY instruction may only be used in error handlers Remove it 40097 Instruction error Task 16s TRYNEXT only allowed in error handler Check The TRYNEXT instruction may only be used in error handlers Remove it 40098 Parameter error Task 16s switch parameter must have transfer mode IN Check Remove the parameter transfer mode specifier If IN transfer mode is not sufficient change the data type of the parameter 40099 Parameter error Task 16s switch parameter cannot be dimensioned Check Remove the array dimension specification or change the data type of the parameter 40100 Parameter error Task 16s switch only allowed for optional parameter Check Change th
121. part Change value 110505 Argument error Argument s has a not allowed negative value Check Set argument s to positive 111000 Weave pattern error Weave interpolation type error Geometric 0 Rapid 1 Check Adjust weave parameters User s Guide Base Ware OS 3 1 111001 Weave pattern error Weave pattern shape error No shape 0 Zig zag shape 1 V shape 2 Triangular shape 3 Check Adjust weave parameters 111002 Weave pattern error Weave pattern cycle length error 0 1 m Check Adjust weave parameters 111003 Weave pattern error Weave pattern cycle time error 0 100 s Check Adjust weave parameters 111004 Weave pattern error Weave pattern width error 0 1 m Check Adjust weave parameters 111005 Weave pattern error Weave pattern height error 0 1 m Check Adjust weave parameters 111006 Weave pattern error Weave pattern left dwell error 0 1 m Check Adjust weave parameters 111007 Weave pattern error Weave pattern center dwell error 0 1 m Check Adjust weave parameters 111008 Weave pattern error Weave pattern right dwell error 0 1 m Check Adjust weave parameters User s Guide BaseWare OS 3 1 System and Error Messages 111009 Weave pattern error Weave pattern bias error 1 1 m Check Adjust weave parameters 111010 Weave pattern error Weave pattern direction angle error PI 2 PI 2 rad C
122. reserved exclusive rights to one or more functions in the system the system input request will be denied The signals MotorOff and Program stop signals from the system Input are active in Manual mode also Some examples of the signal sequences are described below To verify that the robot is in automatic mode Signal sequence AutoOn Out To switch the robot to MOTORS ON state Requirement Robot in MOTORS OFF state and Runchain is closed RunchOK Signal sequence 1 MotorOn IN Order 0 1 MotorOn OUT Response 0 12 26 User s Guide System Parameters To switch the robot to MOTORS OFF state Requirement Robot in MOTORS ON state Signal sequence 1 MotorOff IN Order 0 1 MotorOff OUT Response 0 If the program is running CycleOn the MotorOff action will stop execution of the program To start the program from the beginning of the main routine Requirement Robot in MOTORS ON state and program control not occupied by any other resource e g external computers Signal sequence 1 StartMain IN Order 0 1 CycleOn OUT Response 0 To start or restart program execution from the current instruction or after a power failure Requirement Robot in MOTORS ON state and program control not occupied by any other resource e g external computers A PFError indicates that a power failure error has occurred Signal sequence
123. selecting the pick list and pressing PreviousPage fa or NextPage You can also choose 0 to go directly to the next page e Remove the instruction pick list by choosing Edit Hide IPL User s Guide 8 15 Programming and Testing 8 16 5 2 Adding an instruction If a new instruction is added it is placed after the instruction that is selected If the selected instruction is first in a routine or in a compound instruction IF FOR WHILE or TEST you can choose whether you want the new instruction to be placed before or after the instruction by means of a question However if there is only one instruction in the routine or in the compound instruction new instructions will always be added after the selected one e Select the place where you want the new instruction to be added e Call up one of the instruction pick lists by choosing the appropriate pick list from the IPL1 or IPL2 menu If you want to call up the instruction pick list that was used most recently choose Edit Show IPL The pick list will be displayed on the right hand side of the window see Figure 11 File Edit View IPL1 IPL2 Program Instr WELDPIPE main M C 1 1 26 Init data 1 MoveL counter 0 2 Moved Go to start position 3 Movec MoveL pstart v500 FINE gripf4 procCall WaitUntil dil 1 5 Set Start 6 Reset Set startsignal 7 open_gripper 8 Incr MoveJ v500 z10 gripper 9 Mo
124. show hide an instruction pick list see page 8 15 User s Guide Quick Reference The Program Window 3 2 3 Menu View View Instr lt latest routine gt Routines Data lt latest type gt Data Types Test Modules OU RWN EH NJ Main Routine 8 Selected Routine 9 Error Handler Command Used to view Instr instructions for the current routine Program Instruction window see page 8 12 Routines all routines Program Routines window see page 8 9 Data program data Program Data window see page 8 45 Data Types all data types Program Data Types window see page 8 45 Test the Program Test window see page 8 22 Modules all modules Program Modules window see page 8 55 Main Routine instructions for the main routine see page 8 12 Selected Routine instructions for the selected routine see page 8 12 Error Handler error handler of the current routine see page 8 52 User s Guide 18 9 The Program Window 3 3 Window Program Instr Instructions gt File Edit View IPL1 IPL2 Program Instr WELDPIPE main 1 26 Init data counter 0 Go to start position MoveL pstart v500 fine gripper WaitUntil dil 1 Start Set startsignal open_gripper MoveJ v500 z10 gripper Copy Paste OptArg Modpos Test gt Quick Reference Go to the window Program Test 3 3 1 Menu IPL1 shows differe
125. slower than poll rate 120008 No more BOSCH connection available 120010 Spot gun error Reason s 120011 Spot gun bad config Reason s 120012 IO signal missing Check 1 Configure the mandatory signals used 120013 PERS var missing the swtimer sys module doesn t fit with this kind of gun Check 2 Replace it 120014 Error Number d Check See Ne gun manual 120057 Gun jog forbidden Gun jogging is not allowed when axis not synchronised Check 1 Axis calibration state 120058 Gun Calibration Ok User s Guide Base Ware OS 3 1 120060 Gun Position Error Gun can t reach the position reference Check 1 The drive for power on 2 The encoder 3 Mechanical parts or stuck tips 120061 Gun refer overrun Swit timer can t consume the position reference received Check 1 Swit timer is welding and a move instr is executing concurrently 120062 Gun Force error Gun can t apply the force reference Check 1 Make a gun init 2 Drive and force sensor calibration 120063 Gun Refer underrun Swit timer has no more reference to consumme Check 1 Serial link and comm log error 120064 Gun Force sensor fault force sensor out of order Check 1 Force sensor wiring 2 Change sensor 120065 Gun motor overcurrent motor current too great Check 1 Drive calibration 2 Mechanical unit or obstacle 120066 Gun reference fault gap between references too great Check 1 Robot or gu
126. sranti ie sae EAR E E E EO EE 3 1 2 The main rotte s ace e a E A E Eanes Mis aie E 3 1 3 Operating the SUPPer cts Cs eae E A A a S 3 1 4 Fetching a part from the In feeder o c ccscccesicscasaccssadescndeceds oncsanee costae tasuteca vcededaraceseas 4 1 5 Leaving the part in the machines ja sslveitink nda tad eet ae nadie 4 16 Startins to proces S uiye eges e e e ted ghey a yes a a i e n dahon eae caess 5 1 7 Fetching the part from the machine sssessesssesssesesseeesseesseesseesseresseeesseesseesseessee 5 1 8 Leaving the part on the Out feeder us sscc ssdeassasssessndbansnczedess dosteeduaraceesndzedeannoosasedebane 5 2 Material Handling sseoesssoossssoossssocecsssscessscossssoocessoccessssecessscossssoossssooecessscesssscossssoosse 7 Za What the robot COS cx cstrrins penta tose 2 tt o E E E ES 7 De MING VIAN HOG a e dtu estas E a uae tou aes sams aseisa de coaee 7 2 5 Operating the Sripper seieun ringera eadisseassusiad E ERE E EE aaaea iins 8 24 Startins Produc On esiin n e etn A A E RR 9 2 5 Fetching the part from the In feeder s cs cvssvecscsteraseaestaavsasedeodacas sudesanayeasnenetvenenguenes 9 2 6 Leaving the part in the machine seessseessssesessessesressessresressersresreesernseserssresseseresee 9 2 7 Updating operating statistics s c scccaivscovessasaieatserpeveisaiveenccessaszesasdevedeadeonaceesatseeeseces 10 2 8 Stopping production for the day esessseessssesessessresressessresressesstesreesersresers
127. that appears choosing an alternative from the function keys fields marked with 5 All parameters together with possible values are described in the following sections under the appropriate topic Note You will have to restart the robot in order for the change to have an effect on some parameters You will be informed of this the first time you change such a parameter and when you exit the system parameters i e change window 1 3 Deleting a parameter e Select the parameter to delete Press Delete lt j e Press OK to confirm the delete 1 4 Generating a restart You have to restart the robot in order for a change to have an effect on some of the parameters If you exit the system parameters without generating a restart the param eter values will not be the same as those used in the robot Nevertheless if you generate a restart at a later stage then the changes will take effect e Choose File Restart and press OK or turn the mains switch off and then on again An error message will be displayed when there is an error in the parameters However this can be due to a sequential error The origin of an error can be found by looking at the robot s error logs See chapter 14 Service Logs User s Guide System Parameters 1 5 Viewing the last changes that were made e Choose Edit Show Change Log A dialog box appears displaying the changes that were last made see Figure 2
128. the joint in opposite direction 50031 Command not allowed System parameters cannot be changed in MOTORS ON state Check Change to MOTORS OFF User s Guide BaseWare OS 3 1 System and Error Messages 50032 Calibration command error An attempt was made to calibrate while in MOTORS ON state Check Change to MOTORS OFF 50033 Commutation command error An attempt was made to commutate the motors in MOTORS ON state Check Change to MOTORS OFF 50035 Synchronization error An attempt was made to synchronize in MOTORS ON state Check Change to MOTORS OFF 50036 Correct regain impossible Correct regain impossible A stop occurred with too many close points with corner zones At restart the robot will move to a point farther forward in the program Check Reduce the number of close points increase the distance between them or reduce the speed 50037 MOTORS ON order ignored MOTORS ON order ignored since the previous stop was not yet acknowledged Check Order MOTORS ON again 50041 Robot in a singularity The Robot is too close to a singularity Check During program execution use SingArea instruction or joint interpolation During jogging use axis by axis 50042 System error Check Increase the distance between close points and or decrease speed and or change acceleration value 16 77 System and Error Messages 50050 Position outside reach Position for IRB joint f is outsi
129. the robot memory and added to the rest of the program 13 6 Deleting program modules from the program e Open the window Program Modules by choosing View Modules e Select the desired module e Press Delete X Note An answer must be given to the password check and confirmation dialog if they have been set to active in the configuration The default set up is no password but with confirmation 13 7 Listing all routines in all modules Usually only the routines contained in the current module are displayed in the Program Routines window You can however change this so that all routines in all modules are displayed User s Guide 8 57 Programming and Testing 8 58 e Open the window Program Routines by choosing View Routines e Choose Routine In System To list only the routines in the current module again choose Routine In Module 13 8 Duplicating a routine from one module to another e Choose the module in which the new routine is to be included e List all routines by choosing Routine In System in the Program Routines window e Select the routine to be duplicated e Continue in the normal way as described in Duplicating a routine on page 11 13 9 Listing all data in the current module Usually the data contained in all modules is displayed in the Program Data window You can however change this to display only the data in the current module e Open the window Program Data by choosing Vie
130. to a place holder 40063 Data declaration error Task 16s Place holder for initial value expression not allowed in definition of named persistent Check Complete the data declaration or change the data name to a place holder 40064 Routine declaration error Task 16s Place holder for parameter not allowed in definition of named routine Check Complete the parameter declaration remove the place holder or change the routine name to a place holder 16 55 System and Error Messages 40065 Reference error Task 16s Place holder for type not allowed in definition of named data record component or routine Check Complete the data or routine declaration or change the data or routine name to a place holder 40066 Data declaration error Task 16s Place holder for initial value expression not allowed in definition of named variable Check Complete the data declaration or change the data name to a place holder 40067 Type error Task 16s Too few components in record aggregate of type 18s Check Make sure that the number of expressions in the aggregate is the same as the number of components in the record type 40068 Type error Task 16s Too many components in record aggregate of type 18s Check Make sure that the number of expressions in the aggregate is the same as the number of components in the record type 40069 Reference error Task 16s Data reference 16s is ambig
131. units may be activated at the same time as long as they do not have the same logical axes defined in their set of external axes However two or more mechanical units may have the same logical axes if they are not activated simultane ously Two or more mechanical units may not be activated at the same time if they share one or more drive units even if they use separate logical axes This means that two logical axes each belonging to different mechanical units may control the same drive unit but not at the same time 2 2 Coordination A mechanical unit may be coordinated or not coordinated with the robot movements If it is not coordinated each axis will be moved independent of the robot movements e g when jogging only the separate axis will move However during program execu tion the external axes will be synchronized to the robot movement in such a way that both movements will be completed in the same time If the mechanical unit is coordinated it is guaranteed that the robot TCP movements as seen in the object or user coordinate system will be the same irrespective of the movements of the external axes Two types of coordination categories exist The first category of coordination is when the robot itself is moved e g the coordination to a gantry or track movement This means that the robot is mounted on a gantry or a track and may be moved along these axes The world and user object coordinate systems however will be fix
132. values of the chosen position are displayed see Figure 27 View Program Run Position PROG1 Speed 50 Running Continuous Robtarget pos10 Tuni P t uning resen 1 3 as 0 00 XX XX mm y 0 00 yy YY mm Z 0 00 ZZ ZZ mm gt Tune Figure 27 The Program Run Position window with a robtarget selected e Choose the x y or z coordinate in the list e Press Tune A dialog box will appear where you can tune the position e Enter the desired tuning value and press Enter No change 0 Maximum change in one step 10 mm Several steps can be entered The position data is changed immediately after each step User s Guide 8 32 Programming and Testing but will not affect the robot path until the next instruction using this position data is executed The values in the Present column will be used in this instruction The total tuning will be displayed in the Tuning column Note Ifa named position data is modified all instructions which refer to that position data will be affected Unnamed positions marked as in the instruction cannot be tuned 8 4 Changing an argument e Select the argument that is to be changed e Press Enter lt The dialog box used to program instruction arguments appears and the selected argument is marked with in front of it see Figure 28 SSS Instruction Arguments reg1 reg2
133. window is used for programming An instruction that does not fit into one line is only displayed in part Arguments that lie outside the visible area are moved successively inwards from the right when the various arguments are selected 4 3 What is an instruction An instruction defines a specific task that is to be carried out when the instruction is executed for example Moving the robot Setting an output Changing data Jumping within the program Instructions comprise an instruction name and a number of arguments The name specifies the principal task of the instruction and the arguments specify the characteristics An argument may be either compulsory required or optional Optional arguments may be omitted and are specified by the name of the argument and its value if it has one For example Instruction Meaning MoveL p1 v500 fine tool1 Moves the TCP linearly to the position p The arguments v500 fine and tooll specify the current speed position accuracy and tool SetDO do2 1 Sets the output do2 to 1 SetDO SDelay 0 5 do2 1 Sets the output do2 to 7 with a delay of 0 5 seconds SDelay is an optional argument do2 and 1 are compulsory An argument that does not have a specified value is marked with lt gt Programs that contain such instructions i e incomplete instructions can be executed but program execution stops when that type of instruction occurs User s Guide 8 13 Programming an
134. you can find it in the log see Service in Chapter 14 of this manual 1 2 Calling up suggestions on how to correct an error e Press Check Information about possible corrective measures is displayed along with the reason for the error see Figure 2 User s Guide 16 21 Error Management Error 50028 Motion Jogging error Jogging was made in wrong direction when a joint was out of working range Use the joystick to move the involved joint into the working range again Log OK Figure 2 Suggestions on how to correct an error e Press Log to display the log instead of the check list 1 3 Acknowledging warning messages Sometimes a warning or information message will be displayed This message is dis played in the form of a minimised alert box that conceals only part of the previous win dow e Acknowledge the message by pressing Enter lt 16 22 User s Guide System and Error Messages CONTENTS Page Operational error messages sseessecesocesoocssecssccesocesooseooecssccssocesooesoosesoesssecssocesocesooesssessse 7 System error Messages se ssesocesecsoesooesosssesoesoossoessesooesocsoesoossoessessossooesessossoossessossoossessss I Hardware error Messages eeessseocecssocccesoccessscoeessoocessooecesooccesssoossesooeesssseeesssesessseosssssse LO Program error MESSAGES ss scacisecisdivascssiaiaccairsciasdsnctwideivedsaccsaibvasistsheelaadiuatsheasisecenacrienni OL Motio
135. 0 Bus Type incompatible DescriptionReason Unit s has a type that isn t compatible with it s bus Check 1 Change the bus for the unit 2 or change the unit type 71001 Duplicated address DescriptionReason Same address for unit s and s Check 1 Check the address 2 Check the bus 71002 Invalid unit type DescriptionReason Unit s has an unspecified unit type named s Check 1 Check the unit type against the one specified for the unit 71003 Invalid unit DescriptionReason The unit specified for the signal s is not specified in the unit section Check 1 Change the name of the unit 2 Add a new unit to the unit list 16 90 71004 Invalid signal length DescriptionReason The length of the digital signal s must be 1 Check 1 Change the length to 1 or remove the statement 71005 Filter time invalid DescriptionReason Signal s The passive filter time should be 0 or d d ms Check 1 Change the filter time 71006 Filter time invalid DescriptionReason Signal s The active filter time should be 0 or d d ms Check 1 Change the filter time 71007 Logic value out of range DescriptionReason Signal s Logical Max is less or equal to Logical Min Check 1 Correct the values to be max greater than min 71008 Phys value out of range DescriptionReason Signal s Physical Max is less or equal to Physical Min Check 1 Correct the values to be max great
136. 12003 Board eipaw error Incorrect wirefeeder port length Check Change length 112004 Board eipaw error Schedule number zero is not allowed Previous number will still be active Check 113000 Equipment config error Check AW and EIO configurations do not match 114000 Weldguide error Check Check weldguide parameters and equipment 16 104 115000 Arcitec Data Error Invalid parameter_id 16s detected Check Check Arcitec configuration file or Power Source external communication 115001 Arcitec Data Error Invalid unit_id 16s detected Check Check Arcitec configuration file or Power Source external communication 115002 Arcitec Data Error Invalid transmission length 16s detected Check Check Arcitec configuration file or Power Source external communication 115003 Arcitec Data Error Invalid selection_id 16s detected Check Check Arcitec configuration file or Power Source external communication 115004 Arcitec Data Error Arcitec systems with different units 16s and 16s Check Check Arcitec configuration file 115005 Arcitec Data Error Units not defined for Arcitec system Check Check Arcitec configuration file 115006 Arcitec Data Error Illegal number 16s of tuning parameters Check Check Arcitec configuration file 116000 Track error Check Check joint definition User s Guide Base Ware OS 3 1 116001 Track start error Check Chec
137. 2D2 8 2 1 2 1 1 MNIM2D12 8 2 1 2 0 1 MN2M2D1 9 2 2 1 0 2 MN2M2D2 9 2 2 2 2 2 MN2M2D 12 9 2 2 2 0 2 MN3M2D1 10 2 3 1 0 2 MN3M2D2 10 2 3 2 2 1 MN3M2D 12 10 2 3 2 0 1 MN4M2D1 11 2 4 1 0 2 MN4M2D2 11 2 4 2 3 2 MN4M2D 12 11 2 4 2 0 2 MN5M2D1 12 2 5 1 0 2 MN5M2D2 12 2 5 2 3 1 MNSM2D 12 12 2 5 2 0 1 MN6M2D1 7 2 6 1 0 2 MN6M2D2 7 2 6 2 1 2 MN6M2D 12 7 2 6 2 0 2 Parameter value must not be changed Is connected physically to node 4 but the logical value in the system parameters must be 7 A mechanical unit is now created for each axis Its name will be the same as in the file e g MN4M1DI1 e Now restart using File Restart Do not worry about any error codes which are caused by drive system parameters that have not yet been updated e Choose Area Manipulator e Choose Types Mechanical unit and specify the following User s Guide 12 65 System Parameters 12 66 Parameter Description Name Name of the unit max 7 characters This name will be used later in the Jogging window and in the program e g when a unit is activated Standby state The unit is controlled and the brakes are released not until the first movement instruction is executed or until it is moved manually Must not be deactivated in the S4C system Activated when starting Unit is automatically activated when starting Deactivate not allowed Unit must not be deactivated e Choose Types Single Type and specify under parameter Mechanics TRACK
138. 3 add 8 16 change 8 29 copy 8 21 delete 8 36 move 8 21 instruction pick list 8 15 Most Common 8 60 Instructions 8 12 IO Boards 12 9 IPL1 8 15 IPL2 8 15 I Start 14 11 J jogging 6 3 Joints 12 66 joystick 4 10 6 4 Joystick lock 6 5 L Load parameters 12 7 load module 8 57 program 8 7 11 4 User s Guide Load Program 11 4 Load Saved Parameter 12 7 locking of joystick axes 6 5 Log 14 5 log 14 4 logical expression 8 18 M Main Routine 8 12 main routine 8 5 Manipulator parameters 12 53 MANUAL FULL SPEED 4 9 manual mode 5 5 MANUAL REDUCED SPEED 4 9 Mark 8 30 Mirroring 8 39 modify argument 8 33 data 8 50 instruction 8 29 position 8 31 ModPos 8 31 module 8 54 create 8 56 declaration 8 56 delete 8 57 open 8 57 read 8 55 save 8 58 Module List 8 59 Modules 8 55 Most Common I O list 7 4 instruction pick list 8 60 Motion Supervision 6 5 12 55 Motor parameters 12 53 12 54 12 79 12 81 Motors off 5 5 Motors on 4 9 5 5 Move File Manager 13 7 move files 13 7 instruction 8 21 Move cursor to PP 8 26 Move PP to cursor 8 26 Move PP to Main 8 26 20 3 Move PP to Routine 8 26 MoveC 9 3 Move J 9 3 MoveL 9 3 N New 8 6 module 8 56 New Directory 13 5 new routine 8 10 O object coordinate system jogging 6 11 offset 9 6 Open module 8 57 program 8 7 operating mode 5 4 operator dialogs 11 9 operator s panel 5 4 OptArg 8 34 optional argument 8 13 add 8 3
139. 4 1 3 Defining the Most Common VO list 4 4 4 0 eee eee nA Che 4 2 Chanting Signal VALUES seas ss cco eis veda vadesceu pace ceesunusdugs ss seaeae os cacevesds duce cesneeeveesiaedenssxsenesdse 6 2 1 Changing the value of a digital OUtPUL eee eee ceseceeeeeeneecaeceseetseeeeneessaeenes 6 2 2 Changing the value of an analog output signal or a group of output signals 6 3 Displaying InfOrMmati Onin secsccsvessicsvcvsssassveresssucesesasevscsscecncessvnnsossuuseveeesesvece sosevseesnsoosecstes 7 3 1 To display information on a given signal eecceeeseecseececeeececseececeeeeecseeeenaeeeenes gi 3 2 To display a chart of all digital signals of a unit eeeeeeeeeeeeeeesressesrerersrsrse 7 9 0 To pintan VO st assieme E R E E E E E 8 User s Guide 7 1 Inputs and Outputs 7 2 User s Guide Inputs and Outputs Inputs and Outputs 1 General The robot can be equipped with both digital and analog signals The signals are named and configured in the system parameters They can also be assigned various system actions e g program start In addition to this the robot can communicate with printers and computers via serial channels and Ethernet 1 1 The Inputs Outputs window e Press the Inputs Outputs key to open the window The window displays a list of appropriate signals or units It also provides information on the values of the signals See the example in Figure 1 File Edit View Inputs Outputs I
140. 4 93 AVIS WINS all LO OS 2 ces a racic analyse a e a cn dasea setae eve seagate eeesaens 5 3 4 Viewing a m ssage ina lofst ie a e e a sas SS 6 3 5 Erasing the contents of a l0g sssesseseesseesseessessseressseessresseessresseresseeesseesseesseessees 6 3 6 Erasing the contents of all logs es sssessessesseessseeesseesseesseesseresseeesseesseesseesseeesseee 6 3 7 Updating the contents of a log automatically or by means of a command 7 3 8 Avoiding normal error reports cc cacessscevesads iceeseiheveneds jucesasadcees ees auedacducbonds cacaameeseves 7 3 9 Saving log messages on diskette or some other mass storage device 0 7 A CalibratiO t ccicicccecccescscsdscccceccdccssdscedeceseescbcctesa esscceccded stadsed ccs cdcccetadcbdccsdcdcscstatesssd sedecessas 0 AT What 1s Cali bration ccc aitstesfaktetcSedetonde ates a a e det oa eee nels 8 SCM UC AON is idsccciscelacccsiaccecsdaccsescascssecdscscecsedscocececeUelescedioese scaccsoccdecoescsCedesescecasesescstcesesc 9 Duh Wilatas commutation s s 08 Mrcacse tected case tetsu a aa a a ia aaa 9 6 FErame Definition siccasss cscesiesastanastasceeosssecdhenssdasaschonceasaeanetangnsite bug seincsecabaceaeuascabessnaauasseus gt 7 Two AROS Definition 5 ouceedssenccsscatscesnxsod cass cevenccve cans agonveuneces cemsecvonsobeany sereecenserkachesersaceoveabcuen oO 8 Obtaining information on the robot SysteM ccccsccssssccssssscssssscssssccssssscsss
141. 4 Optional Package 12 45 output instruction 9 7 output signal define 12 12 override speed 11 5 P parameters 12 3 12 9 12 62 pass code change 12 47 define 12 47 Paste 8 21 persistent 8 45 position instruction 9 3 modify 8 31 read current 6 4 power failure 5 3 power supply 5 3 Preferences I O window 7 4 program window 8 60 8 62 20 4 print 1 O list 7 8 program 8 29 ProcCall 9 10 procedure 8 9 Production mode 4 9 Production window 11 3 program 8 5 create 8 6 load 8 7 11 4 print 8 29 save 8 28 program data 8 5 Program Data Types window 8 46 Program Data window 8 45 program flow instructions 9 10 Program Instr window 8 12 program module 8 54 Program Modules window 8 55 Program Routines window 8 9 program running mode 11 5 Program Test window 8 22 program window 8 6 programming 8 5 Programming mode 4 9 P Start 14 11 R RAM disk 13 3 ramldisk 13 4 range of movement limit 12 54 read module 8 55 8 57 parameters 12 7 program 11 4 Relays 12 68 12 69 Rename file 13 5 reorienting the tool 6 9 Replace 8 37 required argument 8 13 Reset 9 7 reset emergency stop 5 6 restart 5 3 12 4 14 11 Rev Counter Update 10 8 User s Guide Robot parameters 12 60 12 61 12 75 12 76 12 83 12 84 12 85 12 86 12 87 routine 8 5 8 8 choose 8 12 create 8 10 declaration 8 35 delete 8 36 duplicate 8 11 8 58 Routines 8 9 Running mode 12 51 running programs production 11 3 testing programs 8 21
142. 5 mm Unit Robot Motion Linear Y 244 9 mm Ze 12 8 mm ql 0 7071 Coord Base q2 0 0000 Tool tool0 q3 0 0000 Wobj wobj0 q4 0 7071 Joystick lock None xz y Incremental No 5 gt No Small edium Large User Figure 22 Selection of incremental jogging If you press the Small Medium Large or User function key the No in the Incremental field will be immediately replaced The robot will then move one step at a time each time you move the joystick the size of the steps Small Medium Large or User defined will depend on your choice You can also use the key to turn incremental movement on and off Try operating the robot using the joystick and note how the robot moves More information on manual operation the various coordinate systems etc can be found in the chapter on jogging in the User s Guide If you do not wish to continue this exercise switch off the system as explained in Chapter 12 Switching the robot off 4 24 User s Guide Basic Operation Selecting a Program 7 Selecting a Program This chapter explains how to open choose a program A program is usually made up of three different parts one main routine always present a number of subroutines and program data Only one main routine is permitted per program see Figure 23 RAPID program Program data main routine subroutine 1 Robot positions Counters etc WaitTime 3 MovelL
143. 8 8 2 User s Guide Programming and Testing 13 11 Saving modules on diskette or some other type of mass meMOry 00 58 13 12 Calling up the complete module list eee eesseceeneeceeeeeceeneeceeeeeceeeeeceteeeenaes 59 TA AR ICE EE E A E E A E 60 14 1 Defining the Most Common instruction pick list sseeseeeeeseeeeeeeereeressererrrreeseeee 60 14 2 De faultdata Global Eocal serorea n n ee E E E Bae 61 14 3 Defining programming rule for robot positions ee eee eee eeeeeeeeeeeeeceneeeeeees 62 User s Guide 8 3 Programming and Testing 8 4 User s Guide Programming and Testing Programming and Testing 1 Creating a New Program 1 1 What is a program A program consists of instructions and data programmed in the RAPID programming language which control the robot and peripheral equipment in a specified way The program is usually made up of three different parts amain routine several subroutines program data In addition to this the program memory contains system modules see Figure 1 m Program memory m Program Program data Main Sub routine routines System modules i Figure 1 The program instructions control the robot and robot peripherals The main routine is the routine from which program execution starts Subroutines are used to divide the program up into smaller parts in order to obtain a modular program that is easy to read They are called f
144. A world zone can only be defined once Check Use a worldzone with another name 40665 Too many world zones It is not possible to add the world zone 16s The world zone table is full Check 16 73 System and Error Messages 40666 Illegal world zones Worldzone 16s is defined locally in current routine or in current module Check Only a global entire world zone argument can be used 40667 Illegal world zones Task 16s WorldZone 16s is not entire data reference Check Only a global entire world zone argument can be used 40668 shapedata not in use The 16s argument of the instruction 16s must refer to a defined shapedata Check A shapedata is used to store a volume definition It must have been defined by WZBoxDef WZSphDef or WZCy1Def prior to be used by WZLimSup or WZDOSet 40669 Invalid volume definition The shapedata defined by the instruction 16s doesn t define a valid volume Check Check previous volume definition instruction 40670 Invalid world zone The index of the world zone argument 16s in 16s is not a valid index defined by WZLimSup or WZDOSet 40671 Illegal use of world zone Task 16s 16s argument for 16s must be a temporay world zone 16 74 40672 World zone already in use It is not possible to add the world zone 16s Another world zone with the same name is already defined in the system 40673 I O access error
145. Any condition IF dil 1 OR di2 1 THEN Instructions executed if dil or di2 1 ENDIF To program an IF instruction in order to test an input e Call up the correct instruction pick list by choosing IPL1 Prog Flow e Choose the instruction ZF or Compact IF by pressing the appropriate numeric key A dialog box will appear in which you specify the required data type for the condition see Figure 13 9 12 User s Guide The programming language RAPID Select datatype 1 IF num e g regl lt 5 2 IF signaldi e g dil 1 3 IF bool e g flagl TRUE rarer Cancel OK Figure 13 The dialog box used to select data type e Select IF signaldi and press Enter Alternatively you can use the numeric keyboard to select the figure in front of the desired data type A dialog box will appear in which you can specify the desired input see Figure 14 Expression 1 6 did dil di2 di3 di4 di5 di6 di7 di8 di9 dil0 dill dil2 dil3 dil14 dil5 dil6 Text Func Content Cancel OK Figure 14 The dialog box used to define expression arguments e Select the desired input and press Enter wv The dialog box used to program expressions will be called up again All operators are now displayed in the lower part of the box e Select the operator and press Enter e Enter 0 or 1 directly using the numeric keyboard e Choo
146. C The power supply unit for tools or special power supply units for the machining process User s Guide Safety The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Manipulator A danger of high voltage is associated with the manipulator in The power supply for the motors up to 370 V DC The user connections for tools or other parts of the installation see Jnstallation max 230 V AC Tools material handling devices etc Tools material handling devices etc may be live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 12 Emergency Release of Mechanical Arm If an emergency situation occur where a person is caught by the mechanical robot arm the brake release buttons should be pressed whereby the arms can be moved to release the person To move the arms by manpower is normally possible on the smaller robots 1400 and 2400 but for the bigger ones it might not be possible without a mechanical lifting device like an overhead crane If power is not available the brakes are applied and therefore manpower might not be sufficient for any robot AN Before releasing the brakes secure that the weight of the arms not enhance the press force on the caught person 13 Limitation of Liability ABB Robotics that the industrial robot will not cau
147. Device conflict Status conflict for the Enabling Device chain Check Please check the two channel safety guard that caused the status conflict 20225 Auto Stop conflict Status conflict for the Auto Stop chain Check Please check the two channel safety guard that caused the status conflict 20226 General Stop conflict Status conflict for the General Stop chain Check Please check the two channel safety guard that caused the status conflict 20227 Motor Contactor conflict Status conflict for the Motor Contactor chain Check Please check the two channel safety guard that caused the status conflict User s Guide Base Ware OS 3 1 20228 Ordered ES conflict Status conflict between ordered and configured type of Emergency Stop Turn Off immediate or delayed Check Replace Panel Board 20229 Ordered AS conflict Status conflict between ordered and configured type of Auto Stop Turn Off immediate or delayed Check Replace Panel Board 20230 Ordered GS conflict Status conflict between ordered and configured type of General Stop Turn Off immediate or delayed Check Replace Panel Board 20231 Delayed ES conflict Status conflict between ES1 and CH1 or ES2 and CH2 after a delayed Emergency Stop Check Replace Panel Board 20232 Delayed AS conflict Status conflict between AS1 and CH1 or AS2 and CH2 after a delayed Auto Stop Check Replace Panel Board 20233 Delay
148. Displacement Frame In the system variable C_PROGDISP set up by instruc tions PDispSet or PDispOn etc Object Frame Robtarget frame Programmed position When a position is programmed Program Displacement Frame Base Frame of a mechanical unit only for internal system use Service View BaseFrame In the base frame definition of an external mechanical unit or as configuration parameter World Frame Wrist Frame Implicit in the kinematic model of robot Base Frame of the robot Tool Frame Tool mounted on robot Program View Data Types tooldata In any tool data Wrist Frame Tool Frame Tool fixed in room Program View Data Types tooldata In any tool data World Frame User s Guide Now any programmed position e g p1 will be related to the World Coordinate system through the chain world frame user frame object frame program displacement frame p1 The current position of the robot i e the location of the tool is related to the World Coordinate system through the chain world frame base frame kinematic model wrist centre frame tool frame 10 3 Calibration When the robot is moved in automatic mode to a programmed position the aim is to bring the tool tool frame to coincide with the programmed position i e to close the chain user frame object frame program displacement frame p1 world frame base frame kine
149. FWD BWD Modpos Instr gt Figure 46 The first instruction is selected 3 Then move the robot to a new position with the joystick 4 Press the ModPos function key The window in Figure 47 will then appear on the dispaly Warning Are you sure you want to modify the position Yes Figure 47 The warning dialog when modifying a position 5 Press Yes if you want to change the original position specified to the current position of the robot 6 Activate the enabling device and press FWD again to move the robot to the next position Repeat points 3 to 6 and go through all the positions in the training program 7 Test run the program step by step Stop the program in any position and press the Instr function key to terminate the Program Test The window in Figure 48 will then appear on the display 4 44 User s Guide Basic Operation File Edit View IPL1 IPL2 Program Instr EXERCISE main 1 4 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 48 The Program Instr window 13 2 Changing arguments You are now going to change one of the arguments of the first move instruction Changing a Program MoveL which should be highlighted You are going to change the precision of the position 1 Select the fine argument see Figure 49
150. File Extensions User s Guide 12 45 System Parameters e Select the File extension to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value Press OK to confirm Parameter Description Name The name of the extension max 3 characters Description Explains the type of data in the file 6 3 Defining authorisation and confirmation It is possible to limit the access to certain commands by using user levels and associ ated pass codes This means that a function will not be executed unless you have the correct user level It is also possible to define that a command will not be performed until it is confirmed In the robot there are four 4 user levels Operator for functions accessible to all users No pass code needed Service for functions associated with service Pass code needed Programmer for functions related to programming and testing Pass code needed Service amp Programmer For functions needed for both programming and service Pass code needed for either Service or Programmer A pass code can be up to 8 digits long If you try to perform a command and you do not have the correct user level a dialogue will appear as shown in Figure 22 Pass Code Input Service pass code required to be able to continue kkkkkkkk Cancel OK Figure 22 Pass Code Input Dialogue 12 46 User s Guide System P
151. Gulee cess cucarv vw vac dee asanievracapaanessngeveaaees 53 7 1 Defining the commutation offset and calibration offset of the motors 53 7 2 Defining the range of movement and calibration position of each axis 54 7 3 Defining supervision level c ciccieesscssasstecnaedsteacaaseseseaceassnecdenteseeatsaveraccesndeceennnoosaees 54 7 4 Tuning the motion supervision 2 23 shana veto cee seine ee 55 Ta Denning teach Mod Speed g c1es sarssasseeeascaasuctosds teens n a R R 56 7 6 Defining independent MOG mx 25 osycsacsug paces ees sacSs cs gas seesed csc ee dyacaseves tad oud catdnecedesoses 56 Td Definng ari IO AG 5 24sisuseadevsedesecs cecsadengs sven ea losegacasuebad svandscnds sessaned lestaceapeaved uecgantes 57 7 9 Definins alin echeck polntisssse sena A R E 58 T9 De finng external TOLQUE rosins eseese eike is 59 7 10 Defining friction compensation esssssessseessessseessesessetesstessresseesseeesseeesseesseesse 60 7 11 Defining the base coordinate system eeseseesseseeesesssesresseserssressessrssreesesererreeseeee 61 7 12 Defining external manipulators with more than one AXIS eee eee eeteeeeeeeeees 62 7 13 Defining a track motion with coordinated motion 0 0 eee eeeeeeeseeeseceteeeeeeeenees 63 7 14 Defining an external mechanical unit coordinated with the robot eee 63 1 15 Defining external axes cise sidiaseni ticle ea nh nsn 63 7 16 Activate forced gain control for an external axis
152. ID Robot type Program resources OK Figure 5 The system information window e Select a topic using the arrow keys and press Enter Information on the selected topic will be displayed User s Guide 14 9 Service Topic Storage capacity Task state System ID Product ID Robot type Program resources Description All available storage devices are shown in a list containing the device name free space and total size All tasks are shown in a list containing task name and task state Uninitialised Ready Executing or Stopped If a task is stopped or executing the current instruction is displayed The unique system identification code is shown The identification code for all installed products is shown Shows the robot type specification Shows the total program memory before task configuration and the maximum number of persistents e Press Update to update the information 9 Backup and Restore The backup function saves all system parameters system modules and program mod ules in a context If desired all logs are also saved The data will be saved in a directory specified by the user The restore function retrieves data from a backup directory Restore replaces all system parameters and loads all modules from the backup directory A warm start is then auto matically performed 9 1 Perform a Backup e Choose File Backup The Backup dialog will be displayed
153. N wobj_use wobj3 draw_fig ENDIF 8 9 How to adjust the program vertically using the object frame When running your program in the location defined by wobj2 suppose you find it is positioned a little too high The vertical position can be adjusted by moving the object coordinate system a small amount vertically relative to the user coordinate system i e the z coordinate for object is changed E g if the robot is to work a little lower then the z value should be decreased 8 10 Using program displacement 10 42 A program displacement is set with a pose data using a PDispSet instruction This will store the program displacement in a system variable C_PROGDISP holding also dis placement values for external axes The current value in C_PROGDISP is used in all movement instructions and added to the programmed positions The program displace ment is cleared when a PDispOff instruction is executed resulting in no further dis placement A PDispOn instruction will both calculate a new program displacement from the dif ference between two positions and store this displacement in the C_PROGDISP vari able When this instruction has been executed a new program displacement will become active The following example will illustrate how to use a PDispOn instruction in combination with a SearchL instruction to make a movement on different locations depending on the search point The program should do the following Go to a sta
154. N 0 02 0 35 AUTO 0 5 1 57 Figure 18 Maximum regain distances e Select the operating mode to be changed and press Enter User s Guide 12 39 System Parameters e Select the desired parameter and change its value e Press OK to confirm Parameter Mode Tcp_dist Tcp_rot Ext_dist Ext_rot 5 5 System miscellaneous Description AUTO or MAN The maximum TCP distance m The maximum TCP rotation rad The maximum distance for external axes m The maximum rotation for external axes rad Changes to any item in this menu will force the system to restart the program handling part of the system at the next warm start All user programs will be erased and all task modules specified in the configuration will be reloaded e Choose Types System misc All functions already added will be listed see Figure 19 File Edit Topics Types System Parameters Controller System misc Function Value 1 2 SimMenu YES AveragePers 20 ADD Figure 19 System miscellaneous e Mark the function to be changed and change it or add a new one e Press OK to confirm Function SimMenu AveragePers 12 40 Description The WaitTime WaitUntil and WaitDI instructions will generate an alert box in manual mode to make it possible for the user to simulate the instruction and continue to execute the next instruction If this is set to NO no menu will be generated YES is the
155. No configuration For this reason Spd is the recommended configuration Trq In this configuration the controller uses the desired speed and acceleration of the axis to calculate the desired motor torque This requires knowledge of the mass moment of inertia of the axis which must be supplied by the user For this reason this configuration is more difficult to tune It is only recommended for experienced users This parameter should be left at its default value This parameter should be left at its default value Dynamic factor This parameter is only available in the Trq configuration It can be used to damp oscillations of the axis due to mechanical resonance Initially Df should be left at its default value It can be adjusted once the other controller parameters have been fixed This parameter should be left at its default value Total mass moment of inertia The amplification of the position control e g 15 A high value will give a stiff axis that quickly assumes its new position The value should be large without inducing overshoot in the position or oscillations of the axis The amplification of the velocity control e g 2 A high value gives better high frequency stiffness better response speed and low overshoot If the value is too high the axis will vibrate User s Guide System Parameters Ky controls the amount of damping for the axis and is the most limiting of the parameters A poor value of Kv will limit Kp a
156. O list name All signals Name Value YP 4 64 dil 1 DI di2 0 DI gripl 0 DO S grip2 1 DO T O list grips i Do bo grip4 1 DO progno 13 GO welderror 0 DO 0 1 Figure 1 The Inputs Outputs window displays a list of selected signals or I O units The information displayed in the window is automatically updated every other second User s Guide 7 3 Inputs and Outputs 1 2 Choosing an I O list e You can decide which signals you want to look at by choosing any of the lists from the View menu List name Most Common All signals Digital In Digital Out Analog Groups Safety Units T O Unit name Group name Information in the list The value of the most important most used signals This list can be customised to suit any robot installation The value of all signals The value of all digital input signals The value of all digital output signals The value of all analog input and output signals The value of all groups of digital signals The value of all safety signals The type and address of all I O units The value and position of all signals of a unit To look at this list e Choose View Units e Select the desired unit and press Enter The value and position of all signals in a signal group To look at this list e Choose View Groups e Select the desired unit and press Enter 1 3 Defining the Most Common YV O list You can obtai
157. Out feeder The main routine is built up of a number of routine calls which reflect the robot work cycle see Figure 4 As the gripper grips and releases parts several times during the program run it is best to set up separate routines for this which can be called from different places in the program routine main fetch_part routine fetch_part leave_in_machine process_part MoveJ vmax z50 tooll MoveL v1000 z30 tooll MoveL v200 fine tool1 fetch_fr_machine leave_part grip MoveL v200 z30 tooll RETURN WaitTime 0 3 RETURN routine release Reset gripper WaitTime 0 3 RETURN Figure 4 For more information about this example see Chapter 17 Program Examples 8 8 User s Guide Programming and Testing There are three types of routines procedures functions and trap routines A procedure could be described as a number of instructions that perform a specific task such as welding a part or changing a tool A function returns a value and for example is used to displace a position or read an input A trap routine is used to deal with interrupts A routine comprises four parts declarations data instructions and an error handler see Figure 5 Routine Name Routine type Scope Function data type Parameters Declarations Data Instructions Error Handler
158. Output Data type num Selection of test output acceptable values are 1 and 2 Signalld Data type testsignal Name of the test signal MechUnit Data type mecunit Mechanical unit for which test signal is required Axis Data type num Axis number Scale Data type num Scaling factor Acceptable values are 1 2 4 8 16 etc Stime Data type num Sampling time in seconds The test output is updated with a new value at each sampling The value 1 denotes one update every second The value 0 denotes updating as often as possible The value 0 01 denotes 100 updates per second User s Guide System Parameters Tuning the Nominal acceleration and deceleration If an axis has a variable moment of inertia Nominal acceleration and Nominal deceleration should be tuned with the maximum inertia If gravity has an influence on the axis then Nominal acceleration should be tuned with a motion accelerating upwards against gravity Nominal deceleration should be tuned with a stopping motion deceleration while moving downwards with gravity Program two test points for acceleration and two test points for deceleration with the following requirements e Velocity Choose a velocity that is approximately 50 of the maximum speed of the external axis i e speed test signal of approximately 2 5 V e Distance The distance should be chosen to ensure that the axis stabilises at the programmed velocity before deceleration 1 Using the chart
159. Parity error channel 2 Check 1 Check communication parameters 2 Replace robot computer board User s Guide BaseWare OS 3 1 System and Error Messages 31135 Framing error channel 2 Check 1 Check communication parameters 2 Replace robot computer board 31136 Noise error channel 2 Check 1 Check communication parameters 2 Replace robot computer board 31137 Error in serial console Received data not equal to transmitted data Check 1 Check communication parameters 2 Replace robot computer board 31138 Overflow serial console Check 1 Check communication parameters 2 Replace robot computer board 31139 Parity error console Check 1 Check communication parameters 2 Replace robot computer board 31140 Framing error console Check 1 Check communication parameters 2 Replace robot computer board 31141 Noise error console Check 1 Check communication parameters 2 Replace robot computer board 31142 Error in tpu channel Received data not equal to transmitted data Check 1 Check communication parameters 2 Replace robot computer board 31143 Overflow in tpu channel Check 1 Check communication parameters 2 Replace robot computer board 16 35 System and Error Messages 31144 Parity error tpu channel Check 1 Check communication parameters 2 Replace robot computer board 31145 Framing error tpu channel Check 1 Check communication parameters 2 Replace robot computer
160. Rename change the name of a selected file see page 13 5 Copy copy a selected file or directory to another mass memory or directory see page 13 6 Move move a selected file or directory to another mass memory or directory see page 13 7 Print File print a file on a printer User s Guide 18 21 The FileManager Quick Reference 5 1 2 Menu Edit Edit 1 Goto 2 Goto Top 3 Goto Bottom Command Used to Goto go to a specific line in a list Goto Top go to the first file in a list Goto Bottom go to the last file in a list 5 1 3 Menu View View 1 ramldisk 2 flp1l Disc 12 Command Used to view ram1disk the files on the RAM disk see page 13 4 flp1 the files on the diskette see page 13 4 5 1 4 Menu Options Options 1 Format 2 Rapid Converters Command Used to Format format a diskette see page 13 7 Rapid Converters convert old program versions 18 22 User s Guide Quick Reference The Service Window 6 The Service Window 6 1 General menus 6 1 1 Menu File File 1 Save logs as 2 Save all logs as 3 Backup 4 Restore Restart Command Used to Save logs as save logs on a diskette or other mass memory see page 14 7 Save all logs as save all logs on a diskette or other mass memory see page 14 7 Backup perform a backup see page 14 10 Restore perform a restore see page 14 11 Restart restart the robot
161. Replace main computer board 37011 Main computer error Check Replace main computer board 37012 Main computer error Check Replace main computer board 37013 Main computer error Check Replace main computer board 37014 Main computer error Check Replace main computer board 37015 Main computer error Check Replace main computer board 37016 Main computer error Check Replace main computer board 37017 Main computer error Check Replace main computer board 37018 Main computer error Check Replace main computer board 37019 Main computer error Check Replace main computer board 37020 Main computer error Check Replace main computer board 16 42 37021 Main computer error Check Replace main computer board 37022 Main computer error Check Replace main computer board 37023 Main computer error Check Replace main computer board 37024 Main computer error Check Replace main computer board 37025 Main computer error Check Replace main computer board 37026 Main computer error Check Replace main computer board 37027 Main computer error Check Replace main computer board 37028 Main computer error Check Replace main computer board 37029 Main computer error Check Replace main computer board 37030 Main computer error Check Replace main computer board 37031 Main computer error Check Replace main computer board 37032 Main computer error Check Replace main comp
162. S server 2 Check the network connection 3 Check the configuration 71099 Trusted NFS server lost DescriptionReason The contact with the trusted NFS server s was lost Check 1 Check the NFS server 2 Check the network connection 3 Check the configuration 71100 Bus table full The number of buses must not exceed d Check 1 Reduce the number of buses 2 Increase the number of buses allowed 71101 Unknown bus name DescriptionReason Board s Unknown bus name s Check 1 Change the bus name for the board at unit type configuration 16 95 System and Error Messages 71102 DeviceNet incompatible DescriptionReason Node d Internal info s od s Check 1 Disconnect the node from bus 2 Contact ABB 71103 Error on I O Bus DescriptionReason An abnormal rate of errors on the s Bus has been detected The connector for Robot CAN I O has been switched off Check 1 Check bus terminators 2 Check I O bus for short circuit 3 Restart system 71104 Error on I O Bus DescriptionReason An abnormal rate of errors on the s Bus has been detected The connectors for External CAN I O and Robot CAN I O has been switched off Check 1 Check bus terminators 2 Check I O bus for short circuit 3 Restart system 71105 Disable group failed DescriptionReason Failed to disable unit s at address d d Check 1 Check I O system parameters 2 Check un
163. Select Value reg2 2 3 New counter_a counter_b regl reg2 reg3 reg4 Next Func More Cancel OK Figure 28 The dialog box used to change arguments In this example the argument reg2 will be changed The argument can now be changed in four different ways by changing a numeric value this alternative is used when a numeric value is to be specified e g 5 or when an argument is to be changed e g from reg2 to reg3 e Select the middle part of the dialog box following and alternately do one of the move the cursor to the left or right using ArrowLeft or ArrowRight _ delete the character in front of the cursor by pressing Delete enter digits at the cursor using the numeric keyboard by choosing data in the lower part of the of the dialog box this alternative is used when the argument is to constitute a reference to data e g reg2 by choosing a function press the function key Func and select the desired alternative from the list This alternative is used when an argument is to constitute a function call e g Offs p1 5 0 0 User s Guide 8 33 Programming and Testing A new dialog box that can be used to program function arguments appears Use the function key Skip to delete optional arguments that are not to be included by entering an optional expression press the function key More this alternative is used when the ar
164. TPWrite ERROR No part in the gripper Write error message on teach pendant EXIT Exit program execution ENDIF GripLoad payload Specify that there is a load The routine release_part is not included in this example User s Guide Program Examples Material Handling 2 4 Starting production Before the actual production is started the counter reg which counts the number of parts that are produced during the day is set to zero The robot also goes into a home position Routine start_production Comments regl 0 Reset the counter MoveJ home v500 fine gripper1 Go to home position In this example all positions e g home or p1 are named They are stored as separate position data and can thus be reused in subsequent instructions However it is often just as easy to store the positions directly in the instructions indicated by in the instruction 2 5 Fetching the part from the In feeder Before fetching a part the robot must check if there is any part to fetch It does this by means of a photocell via the feeder signal This informs the robot if there is a part in position or not If there is no part the operator is sent a message and must first correct the error before starting program execution again Routine fetch_part Comments WHILE DInput feeder 0 DO Check if there is any part to fetch TPErase If not Clear the teach pendant and TPWrite ERROR No part on feeder write error message Then wait u
165. The calibration status can be any of the following Synchronized All axes are calibrated and their positions are known The unit is ready for use Not updated Rev Counter All axes are fine calibrated but one or more of the axes has a revolution counter that is NOT updated This or these must thus be updated Not calibrated One or more of the axes is NOT fine calibrated This or these must thus be fine calibrated Unsynchronized At least one of the axes has a position that is NOT known An external axis with a sync switch must thus be synchronized See Section 5 Starting up in this manual 3 3 Checking the calibration Thus check the calibration very carefully after each update A If a revolution counter is incorrectly updated it will cause incorrect positioning An incorrect update can damage the robot system or injure someone e Run the calibration program under the SERVICE CALIBRAT directory on the system diskette Set up An alternative method is to jog the robot axis by axis until the axis angles in the Jogging window equal zero e Check each axis to see if the marks are positioned exactly opposite one another If they are not the calibration must be redone The marks may be scribed lines vernier scales or the like Their location is described in the chapter on Installation and Commissioning in the Product Manual User s Guide 10 7 Calibration 3 4 Updating revolution counters e Open the Service
166. User s Guide 3HAC 0966 21 For BaseWare OS 3 1 ABB Flexible Automation The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be prosecuted Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge ABB Robotics Products AB Article number 3HAC 0966 21 Issue For BaseWare OS 3 1 ABB Robotics Products AB S 721 68 Vasteras Sweden CONTENTS Page I Table oF C Omens 6 seiisceaccccccisedcccccttucsesscdcecsescnaccestevcesccacesacedesdeccosoetessdcactes 1 1 2 Introduction sssi secssscceasseceasccbevsccscesceeecks castcesece suet ebeceawcesticeachevenescenesetoeasd 2 1 1 New Features in this Version of the Robot csscsssssssscsssssssscssssescsesseeeees 2 3 2 Other Manuals 5 csivcksivescceayasoncneinsacceannccau saost ontos oases otsest osos aae ro a
167. Window title Jogging Robot Pos Unit Robot x 1234 5 mm Motion Linear yY 244 9 mm Z 12 8 mm Field ql 0 7071 A q2 0 0000 oe i q3 0 0000 Wop wobj0 q4 0 7071 Joystick lock None xz y Joystick direction Incremental No y5 gt World Base Tool WOb 4 Figure 20 The Jogging window The appearance of the window changes depending on the type of window selected i e depending on what you want to do The Menu keys perform different commands The list of commands available is dis played in a pull down menu when you press any of the menu keys The area enclosed by a dashed line is called a Field The highlighted shaded grey area is known as an input field and can be changed by selecting a different function using one of the Function keys or in some cases using the Motion keys on the teach pendant The highlighted input field in Figure 20 is marked with a O after it which means that Selection is done using a Function key User s Guide 4 23 Jogging the Robot Using the Joystick Basic Operation 2 Move the cursor the shaded field to the Incremental field using the Down arrow key on the teach pendant see Figure 21 A i l Eo Figure 21 The Down arrow navigation key 3 If you move the cursor to the Incremental field as in Figure 22 you can choose incremental jogging by pressing one the function keys Jogging Robot Pos x 1234
168. a 22 SLA Meni Opt ONS a a Nea a a aa 22 6 The Service WU OW sci ccwiscsssiacocscadessicuss ccascsavesisos ddadosondedvadasdaaeesosecsacesscaddejasdubdodostcaussieveaste 23 Gl General MENUS scx auiveandsanGeule aia den Guna saat at asnaiebhi tina lan aan ted salt 23 Gls Menu Files Tesoro aeo a a a eri Si 23 6 12 Men Editera a a a S 24 6 1 3 Ment VIEW oed oraa e p AE EAEE E O TE 25 6 2 WAN O Wo SET VIC SO 2 Teta A EE E E a E E ne Ba ak 26 6 2 1 M p Sp cial nesine a E E E arena torsos E E 26 6 3 Window Service Calibration ssssssesssssssseesseessesssersseeessstessresseesseresseessseessresseessee 27 6 3 1 Menut Calib y cc sccccssictayercalaness n a R E R R RGE 27 6 4 Window Service Commutation ssessseeeseeesseessessseeessetssseessrssressteesseeessressresseessees 28 6 4 Men COMA eeh it E OE Si ERS 28 7 The System ParametetS osessessssssiscssisosserirorisssesvorsisnsssrssiescn ce sveseysceonsoegnccheenceesevensveeneovdes 29 7 1 Window System Paraimeters s cs sccvecaseesssavaasdsdesadcaasavcade teeeeateaweszceuseeeeentboraatereteaees 29 TAM enu File thes ui a E e E E N T E in 29 Pe eke Menu Edit pe neeesa Tis sa E a E ea a Ei 30 BAe Ais INET TOOLS wea a oy a as Ne n A E 30 TLA Men Ty pesissccdiaicieaaitigsicaasagiadiass cosa eis n iasasdaa ada sedaaasaniad aoa aate A EAEE 31 18 2 User s Guide Quick Reference The Jogging Window 1 The Jogging Window 1 1 Window Jogging
169. a is set to xxxN where xxx describes the data type and N is a number incremented each time this type of data is created The first data of the type clock is named clock the second clock2 etc Some data types are abbreviated e g Data type Predefined name Data type Predefined name num regN loaddata loadN robtarget pN tooldata toolN bool flagN speeddata speedN Current module num Data Def in USER Name reg7 Decl Cancel OK Figure 41 New data is created e Change the name by pressing Enter and specify a new name The data will automatically be given characteristics that are best suited to the current type but these can be changed when necessary Normally data is stored as a part of the program However when data is to be present in the memory irrespective of which program is loaded it is stored in the system module User Examples of this type of data are tools and work objects changing this data will affect all programs registers and other data that are not to be initialised when a program changes When you wish to save in the current module and with standard characteristics you can finish by pressing OK In other cases the characteristic must be defined User s Guide 8 47 Programming and Testing 8 48 e Press the function key Decl A dialog box appears displaying the basic data declaration see Figure 42 num Data Definition Name reg 7 Typ
170. a singularity Work area with kinematic limitations Check During jogging use axis by axis During program execution use MoveAbsJ User s Guide BaseWare OS 3 1 50162 Internal position error Error caused by internal numerical limitation Check Reset independant joint Reduce work area if extended Remove or separate close points 50163 External Pos adjustment External Pos adjustment too large TCP speed orientation speed or external position speed exceed allowed robot performance Check 1 Reduce programmed TCP and orientation speeds 2 Modify the path 3 WaitW Obj closer to sync 4 Run in AUTO 50164 Ind deactivation error Independent deactivation error Deactivation of mechanical unit may not be done while in independent mode 50167 Warning new sync Warning a new object sync signal has arrived while conveyor is active and program is running 50168 New object sync New object sync arrived while conveyor was tracking the previous object Cannot track two objects simultaneously Check Reduce speed of conveyor Increase programmed speed 50170 Process missing External control process missing during initialization Named process s could not be found or initialized Check Check process name in motion and process configuration files User s Guide BaseWare OS 3 1 System and Error Messages 50171 Speed too low Numerical problem when interpolation of long segments with low spee
171. ad 7 10 Defining friction compensation Friction compensation can be activated to reduce path errors caused by friction and backlash at low speeds 10 200 mm s The friction model is a constant level with a sign opposite to the axis speed direction Friction ffw level Nm is the absolute friction level at ow speeds greater than Friction ffw ramp rad s see Figure 30 12 60 User s Guide System Parameters A Low speed motor friction Nm Friction ffw level Nm yee Friction ffw ramp rad s p Axis motor speed rad s Figure 30 Friction model The instruction TuneServo can be used to tune optimal values for each robot axis e Choose Topics Manipulator e Choose Types Control parameters e Select the desired axis and press Enter e Select the desired parameter and change its value Press OK to confirm Parameter Description Friction ffw on Activates deactivates friction compensation Friction ffw level Low speed motor friction level Nm Friction ffw ramp Friction ramp rad s Tuning procedure The most straight forward way to tune the friction parameters is to consider one axis at a time Choose a motion which has a characteristic friction bump due to a specific axis changing direction Turn the friction compensation on for this specific axis and use the default setting for friction level and ramp Use the TuneServo command to gradually increase the friction level unt
172. ailable for the installation in question e Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it Although troubleshooting may on occasion have to be carried out while the power supply is turned on the robot must be turned off by setting the mains switch to OFF when repairing faults disconnecting electric leads and disconnecting or connecting units Even if the power supply for the robot is turned off you can still injure yourself e The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by the tie rod e Energy stored in the robot for the purpose of counterbalancing certain axes may be released if the robot or parts thereof is dismantled e When dismantling assembling mechanical units watch out for falling objects e Be aware of stored energy DC link and hot parts in the controller e Units inside the controller e g I O modules can be supplied with external power 11 Risks Associated with Live Electric Parts 3 12 Controller A danger of high voltage is associated with the following parts The mains supply mains switch The power unit The power supply unit for the computer system 55 V AC The rectifier unit 260 V AC and 370 V DC NB Capacitors The drive unit 370 V DC The service outlets 115 230 VA
173. ailable programs The Mass memory unit field indicates flp1 to denote a diskette ramldisk to denote the robot s internal memory the RAM disk e Press Unit until the desired unit is displayed e Choose the desired program use ArrowUp A or ArrowDown LJ to scroll to go up one level and press 4 to go down one level through the list select e Press OK User s Guide Production Running 3 Changing the Override Speed The speed of the robot can be adjusted while running production The function keys indicate how the speed can be decreased or increased Decreases the value by 5 or 1 if lt 5 Increases the value by 5 or 1 if lt 5 25 Sets the value to 25 100 Sets the value to 100 To override the speed do as follows e Select the middle part of the display by pressing I e Using one of the arrow keys select the field for the corrected speed see Figure 3 Corrected speed in gt Speed 75 Running mode Continuous 2 39 MoveL p1 v500 z20 tooll gt gt MoveL p2 v500 220 tooll MoveL p3 v500 z20 tooll Set dol Set do2 Program list 25 100 Figure 3 The function keys can be used to both increase and decrease the programmed speed e Press the desired alternative e To return to the program list use i 4 Changing the P
174. ain of operation is open the robot always reverts to MOTORS OFF mode MOTORS OFF mode means that drive power is removed from the robot s motors and the brakes are applied Drive M Unit External contactors The status of the switches is indicated by LEDs on top of the panel module in the con trol cabinet and is also displayed on the teach pendant I O window After a stop the switch must be reset at the unit which caused the stop before the robot can be ordered to start again The time limits for the central two channel cyclic supervisions of the safety control chain is between 2 and 4 second AN The safety chains must never be bypassed modified or changed in any other way 3 6 User s Guide Safety 7 2 Emergency stops An emergency stop should be activated if there is a danger to people or equipment Built in emergency stop buttons are located on the operator s panel of the robot con troller and on the teach pendant External emergency stop devices buttons etc can be connected to the safety chain by the user see Product Manual nstallation They must be connected in accordance with the applicable standards for emergency stop circuits Before commissioning the robot all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation AN Before switching to MOTORS ON mode again establish the reason for the stop and rectify the fault 7 3 Mo
175. al s due to communication down Check 1 Check No contact with I O unit report for reason 71140 Parameter act high error DescriptionReason Signal s This type of signal can t be set to active high Check 1 Only output signals can be set to active high 71141 Default out of range DescriptionReason The default value for signal s is out of range Check 1 Change the default value in configuration 71142 Parameter Default error DescriptionReason Signal s This type of signal can t be assigned a default value Check 1 Only output signals can be assigned default values 71143 CTS RTS not allowed DescriptionReason Serie channel s can t have option RTS CTS Check 1 Remove the option from configuration User s Guide BaseWare OS 3 1 System and Error Messages 71144 Enable group failed DescriptionReason Failed to enable unit s at address d d Check 1 Check I O system parameters 2 Check unit 71145 IBS bus deactivated DescriptionReason IBS bus changed into a none running mode Check 1 Check the bus and restart the system 71146 Subscribe error DescriptionReason The maxlimit is less then minlimit maxlimit f minlimit f Check 1 Make the correction and try again 71147 No response dsqc344 DescriptionReason Access to the dsqc344 is denied Check 1 Check dsqc344 board 2 Check dsqc344 internal confiuration 3 Reduce cycle time
176. al axes on page 63 Define the base coordinate system of the track motion from the Service window for example See Chapter 10 Calibration e Choose Types Robot e Select the robot and press Enter e Set the parameter Base frame moved by to the name of the axis single that is used by the defined track 7 14 Defining an external mechanical unit coordinated with the robot e Define the axis in the usual way See Defining external axes on page 63 Define the base coordinate system of the unit from the Service window for example See Chapter 10 Calibration e Choose Types Mechanical unit e Select the mechanical unit to be coordinated with the robot and press Enter e Set the parameter User frame moved by to the name of the axis Single that rotates the work object 7 15 Defining external axes The configuration files supplied must be used for track motion and for manipulators supplied by ABB See the enclosed documentation On the system diskette Control Parameters which is supplied with the robot there are a number of predefined setups of external axes These can be found in the directory EXTAXIS and must be used during installation e Service movement parameters must be used when defining external axes The control program must be re installed to activate these parameters First select the Query mode When the question Service Standard movement parameters comes up choose Service See
177. al form Valid val ues are from 2 to 126 126 is reserved for uninitialised nodes To configure the Profibus master use the GSD file supplied on the diskette Controller Parameters file SERVICE GSD ABB_0600 GSD The modules to be choosen depends on the I O definition 3 3 Defining input and output signals e Choose Topics IO Signals e Choose Types User Signals All named signals will be displayed see Figure 6 File Edit Topics Types System Parameters IO Signals User Signals Name Unit Type Sig 1 96 currentok da327_11 DI 4 di6 d327_11 DI 6 di7 d327_11 DI 7 dol d327_11 DO 1 do2 d327_11 DO 2 do28 d328_12 DO 12 do29 d328_12 DO 13 do32 d328_12 DO 16 Add Figure 6 System parameters of the type User Signals Note that several signals can be connected to the same physical channel The same sig nals cannot however be connected to different physical channels e Select the signal to be changed and press Enter Add pa e Select the desired parameter and change its value e Press OK to confirm To delete a signal e Select the appropriate signal e Press Q or add a new one by pressing User s Guide Parameter Signal Name Unit Name Signal Type Signal Number Logical Max Physical Max Logical Min Physical Min System Parameters Description The name of the signal max 16 characters The unit to which the signal is connected For more
178. ality in this Robot scccsssssssssccescssssssssssescees 19 1 20 Index GLOSS ANY cc ietec esceicsaccstecece sidencccdecess cdc sieecsscusieencatesstedsanceasecescunceace 20 1 1 12 User s Guide Introduction CONTENTS Page 1 New Features in this Version of the RODOt csscccsssscssscccsssscsssescsssscessescsssessesees 3 2 MDUMO IVT AMV UV AALS 2605 5s accede gsc hcvos cabo ccsanch cuss ve vhateoo terest edos cave se aneoeae cans ote 3 3 How to Read this Manual sicsccsesessscosscuescectsccscctonsudikesscieccueuesdacaeslvnccdoucussieeaedscasscecdacnssiveds 3 3 1 Typographic conventions aeaa ea aa a CR 4 4 Reader s C Omaime nats osivee is scescesaevaccess cascccesscasscauosvaccbysdessovdssceeusercaccevens oso S odis tooss iiae aisi 5 User s Guide 2 1 Introduction 2 2 User s Guide Introduction Introduction This manual will help you whenever you use the robot It provides step by step instructions on how to perform various tasks such as how to move the robot manually how to program or how to start a program when running production 1 New Features in this Version of the Robot New functionality and other interesting information can be read from the file readme on the Set up diskette This file is continuously updated with the latest information which is why two robots of the same version may contain different information in their readme files This file can be read from a normal PC using any wo
179. alues are transmitted i e to a terminal or a printer 12 33 System Parameters 4 3 Defining Application Protocol e Choose Topics Communication e Choose Types Application Protocol All defined application protocols will be displayed as shown in Figure 16 12 34 File Edit Topics Types System Parameters Communication Application Protocols Name Type Trans Prot 1 1 rapl RAP slipl Add Figure 16 System parameters of the type Application protocol e Select the application protocol to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value Press OK to confirm Parameters Name Type Trans Prot Description Name of the application protocol max 16 characters The name must be unique and must not be used anywhere else Type of application protocol RAP NFS See Figure 13 Name of the transmission protocol the protocol should use RAP Robot Application Protocol Additionally the following parameters must be set if the Type is set to RAP Remote Address PortNo Send start up msg Enable SUBSCW The IP Address of the Remote Computer This variable is required when sending start up messages If the transmission protocol is SLIP this parameter can be left empty The Remote Address of the SLIP connection is used instead The TCP protocol port number of the remote computer When enabled the rob
180. am Data window you can also press the function key Test The section of the program that will be executed when you start the program is displayed in the window A program pointer keeps up with the program execution This pointer is shown with gt in the program list Program execution normally continues from this point However if the cursor is moved to another instruction when the program is stopped execution can be started from the position of the cursor see Figure 19 File Edit View Special P Test WELDPIPE mai Program and rogram Tes main Test Speed 503 routine name settings _ Running Continuous 1 26 Program pointer Init data counter 0 lt Cursor i Go to start position Instructions MoveL pstart v500 FINE gripper WaitUntil dil 1 Start Set startsignal open_gripper Start FWD BWD Modpos Instr gt 8 22 gt Figure 19 The Program Test window is used to execute a program If the robot is equipped with an arc welding function an extra field with the blocking status will be shown 6 3 Choosing the speed correction When the program is being tested for the first time it is advisable to reduce the speed A 50 speed correction means that the speed will be reduced to 50 of the programmed speed On the other hand when the robot is in manual mode with reduced speed the speed is never more than 250 mm s It is also poss
181. ame to refer to a required parameter 40081 Reference error Task 16s 16s not trap reference Check The specified name identifies an object other than a trap Check if the desired trap is hidden by some other object with the same name 40082 Reference error Task 16s 16s not type name Check The specified name identifies an object other than a type Check if the desired type is hidden by some other object with the same name 40083 Type error Task 16s 16s not value type Check Only variables which lack initial value and VAR mode parameters may be of semi value or non value type 40086 Reference error Task 16s Reference to unknown label 16s Check The routine contains no label or other object with the specified name 40087 Reference error Task 16s Reference to unknown optional parameter 16s Check The called routine contains no optional parameter or other object with the specified name 16 57 System and Error Messages 40089 Reference error Task 16s Reference to unknown record component 16s Check The record type contains no record component with the specified name 40090 Reference error Task 16s Reference to unknown required parameter 16s Check The called routine contains no required parameter or other object with the specified name 40092 Reference error Task 16s Unknown type name 16s Check No data type
182. and path direction 50059 Frame error The definition of robot fixed tool is not correct Check Check the tool and object data 50060 Frame error The definition of robot fixed tool is not correct Check Check the tool and object data 50061 Frame error The definition of robot fixed tool is not correct Check Check the tool and object data 50062 Circle programming error Start and end positions for the circle are too close 50063 Circle programming error The circle position is too close to the start or end position of the circle 50065 Kinematics error The destination of the movement is outside the reach of the robot or too close to a singularity Check Change the destination position 50066 Robot not active Attempt to coordinate motion or calculate position of deactivated robot s Check Activate robot via the Motion Unit key then Jogging window or program Check work object and program User s Guide Base Ware OS 3 1 50067 Unit not active Attempt to coordinate motion or calculate position of deactivated single unit s Check Activate unit via Motion Unit key then Jogging window or program Check work object and program 50076 Orientation def error Orientation is incorrectly defined Check Make an accurate normalization of the quaternion elements 50078 Too many close positions Too many consecutive closely spaced positions Check Increase the distance betwe
183. arameters e Input your pass code for the correct user level e Press OK to confirm the pass code input If the pass code is still not correct press Cancel and ask your system administrator for the correct one Defining new pass codes e Choose Topics TeachPendant e Choose Edit Change Pass Codes e Read the warning message and press OK Change Pass Code Input the old Pass Code before changing to a new Pass Code Old New Operator No Pass Code Service Programmer Cancel OK Figure 23 Pass CodeChange Dialogue e Select the old pass code of the user level to be changed use the arrow keys Up or Down e Input the old pass code the pass code will not be visible After installation of the control program the pass code is 007 e Select the new pass code of the user level to be changed e Input the new pass code the pass code will be visible e Press OK to acknowledge the change of pass code e Press Enter to confirm the updating Defining authorisation To authorise a function e Choose Topics TeachPendant e Choose from the Types menu the window you want to authorise names start with Authorise All functions that can be authorised will be displayed e g as shown in Figure 24 e Select the function to change and press Enter User s Guide 12 47 System Parameters 12 48 Parameter Function User Level Confirm e To change
184. ariable may not be read only 40158 Value error Task 16s Integer value G too large Check The value of the expression must be an integer value The current value is outside the integer range 40159 Value error Task 16s G not integer value Check The value of the expression must be an exact integer value The current value has a fraction part 40165 Reference error Task 16s Reference to unknown entire data 16s Check No data or other object with the specified name is visible from this program position User s Guide BaseWare OS 3 1 System and Error Messages 40166 Reference error Task 16s Reference to unknown function 16s Check No function or other object with the specified name is visible from this program position 40168 Reference error Task 16s Reference to unknown procedure 16s Check No procedure or other object with the specified name is visible from this program position 40170 Reference error Task 16s Reference to unknown trap 16s Check No trap or other object with the specified name is visible from this program position 40191 Instruction error Task 16s Variable and trap routine already connected Check It is not legal to connect a specific variable with a specific trap routine more than once 40192 Argument error Task 16s 16s is second present conditional argument for excluding parameters Check Arguments may
185. as possible to the world fixed tip e Modify the position by pressing the function key ModPos e Repeat the above for the points Approach Point 2 4 To record Elongator Point Z if the 4 point TCP method is not used Select Elongator z Point e Jog without changing the orientation from the last approach point any point on the desired positive z axis to the world fixed tip An extension should be fitted to obtain better accuracy e Modify the position by pressing the function key ModPos To record Elongator Point X only if the 6 Point TCP amp XZ method is used Select Elongator x Point e Jog without changing the orientation from the last approach point any point on the desired positive x axis to the world fixed tip e Modify the position by pressing the function key ModPos To calculate the tool coordinate system e Press OK to calculate the tool coordinate system When the calculation is finished a dialog like the one in Figure 30 will appear 10 32 User s Guide Calibration es Tool Calculation Result Tool tool4 TCP 50 57 0 00 231 82 Calculation Log 1 4 Method 4 points TCP Mean Error 1 12 Max Error 2 31 Quaternion 1 0 978453 File Cancel OK Figure 30 The result of a tool calculation Field Description TCP The values of the calculated TCP Mean Error The average distance that the approach points are from the calculated TCP i e how accurately the robot wa
186. aseWare OS 3 1 System and Error Messages 40107 Data declaration error Task 16s Cannot determine type of variable value circular constant references Check Check that any referred constants are correctly defined If so the program is too complex Try to rewrite the declarations 40108 Type error Task 16s Unknown aggregate type Check An aggregate may not be used in this position since there is no expected data type Declare data with the desired data type and aggregate value Use the name of the data instead of the aggregate 40109 Type definition error Task 16s Cannot determine type of record component 16s circular type definitions Check Check that the type of the component is correctly defined If so it could be a circular definition the type of a component could not refere to the its own record type 40110 Reference error Task 16s Record name 16s is ambiguous Check At least one other object sharing the same name as the referred record name is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40111 Name error Task 16s Global record name 16s ambiguous Check Global type must have names that are unique among all the global types data global routines and modules in the entire program Rename the record or change the conflicting name 16 59 System and Error Messages 40112 Reference er
187. asic Operation 3 2 The manipulator Figure 3 shows the directions in which the various axes of the manipulator can move and what these are called Figure 3 Manipulator IRB 2400 3 3 The controller Figure 4 illustrates the principal parts of the controller Teach pendant wet Operator s panel Disk drive Mains switch sa rn _ aq i Z Figure 4 The S4C control system 4 8 User s Guide Basic Operation System Overview 3 4 Operator s panel Figure 5 below shows a close up of the operator s panel A short explanation of the push buttons follows a 100 Operating mode selector A AUTOMATIC MANUAL REDUCED SPEED N MANUAL FULL SPEED aN Emergency stop O Duty time counter Figure 5 The operator s panel MOTORS ON MOTORS ON In the MOTORS ON state the motors of the robot are activated and the MOTORS ON button is continuously lit Operating mode AUTOMATIC Production mode Used when running ready made programs in production It is not possible to move the robot with the joystick in this mode Operating mode MANUAL REDUCED SPEED Programming mode Used when working inside the robot s working area and when programming the robot Also used to set the robot in MOTORS OFF state Operating mode MANUAL FULL SPEED Testing mode Option not standard Used to test run the robot program at full programming speed Emergency
188. assive and Active time has the range Minimum 100 ms Maximum 32 seconds Step 10 ms A maximum of 128 I O signals can be defined with the Store parameter A maximum of 60 cross connections can be defined User s Guide 12 21 System Parameters 3 8 Defining system inputs The input signals can be assigned specific system actions In this case they will automatically be handled by the robot See also PLC Communication on page 26 System inputs with actions including a MOTORS ON order or Start of any robot movement are allowed in automatic mode only When a system input order is rejected because the system is in manual mode or due to any other unfulfilled requirement no error messages will be displayed on the teach pendant The reason for this is that the teach pendant is normally not being used by the operator in these situations and there is therefore no sense in displaying the messages on the teach pendant However the messages will still be stored in the error log so you may check for an answer there as to why a system input gives no action e If the signal has not already been defined define its name in the normal way See Defining input and output signals on page 12 e Choose Types System Inputs All defined system inputs will be displayed see Figure 11 File Edit Topics Types System Parameters IO Signals System Inputs Name Action 1 4 dis MotorOn di9 MotorOff progstart StartMain servic
189. at the robot is outside of regain distance 20154 Stop instr rejected Stop of program instruction via System IO not allowed 20155 Undefined Argument SyncExtAx mechanical_unit_name is not defined 20156 Undefined Argument Interrupt routine_name is not defined 20157 Undefined Argument LoadStart program_name is not defined 20158 No System Input signal A system input has been declared to a signal that doesnt exist 20159 No System Output signal A system output has been declared to a signal that doesnt exist User s Guide Base Ware OS 3 1 20160 Not in configuration The system module s in task s has no corresponding specification in the configuration for Task modules Check View Task modules in the System Parameter menu and add an item for this system module 20161 Path not find The system module s in task s has a corresponding specification in the configuration for Task modules that point out a non existing file path Check View Task modules in the System Parameter menu and change the path in the item for this system module 20162 Write error A write error occur when the system try to save the system module 14s at 37s in task 16s Or the file system was full Check View Task modules in the System Parameter menu and change the path in the item for this system module 20163 Reconfig failed Some user module s changed but not saved See previous warn
190. ation error Not possible to coordinate user with robot s Function not installed in this system Check Install the option Advanced Motion 50188 Non optimal movement Non optimal movement Required torque too high Manual adjustment of weave frequency or amplitude is needed Check Reduce weave frequency or weave amplitude in this movement Alternatively reduce speed 50189 Relay signal not found The signal s for relay s is not found in the I O configuration Check The mechanical unit using this relay is ignored Check I O signal definitions and System Parameters definition of Manipulator Types Relay User s Guide Base Ware OS 3 1 50190 Permanent ipol lock error Scanned no of active joints not equal expected no of joints Check Check configuration of unit using general kinematics 50191 Too many TCP speed s The number of TCP speedsinone segment is too large Maximum number of TCP speed s is d Check Check if one segment has too many TCP speed s set or if a sequence of segments have increasing DipLag 50192 Jogging error Jogging is started too soon after program stop Check Restart and try again 50193 Joint sync error The speed of joint s before power down failure was too high Check Make a new update of the revolution counter 50194 Internal position error Error caused by internal numerical limitation Log joint number 2 0f Check Dyn step 0 f
191. aviour of movements with the soft servo activated is described in the RAPID Reference Manual Motion and I O Principles There are four system parameters to consider when the soft servo is used for an exter nal axis The parameters are set to default values but can be changed if the system is booted in service mode e Choose Topics Manipulator e Choose Types Lag control master 0 e Select the lag control master corresponding to the external axis e Press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Description K soft max factor Determines the value of the product Kp Kv when the soft servo is used with softness 0 K soft max factor should be in the range 0 1 2 0 default 1 0 When the soft servo is activated with 0 softness the control parameters Kp and Kv will be tuned such that Kp Kv Kp Kv hor mal K soft max factor where Kp Kv 9 mai iS the prod uct of Kp and Kv during normal operation K soft min factor Determines the value of the product Kp Kv if the soft servo is used with softness 100 K soft min factor should be in the range 0 001 0 1 default 0 01 When the soft servo is activated with 100 softness the control parameters Kp and Kv are tuned such that Kp Kv Kp Kv horma K soft min factor Kp Kv ratio factor Factor used to alter the Kp Kv ratio during soft servo Kp Kv ratio factor should be in the range 0 1 1 0 default 1 0 In
192. axes rotational mechanical unit System Info Obtain information about storage capacity task states system and product ID etc 2 Changing the Current Date and Time e Choose View Date amp Time A dialog box will be called up displaying the current date and time see Figure 1 User s Guide 14 3 Service Service Date amp Time Date 1994 26 Feb Time 09 35 10 lt gt Cancel OK Figure 1 The dialog box used to set the date and time e Select that which you wish to change using the arrow keys e Using the function keys lt decreases and gt increases change the date or time e Choose OK to confirm 3 Logs 3 1 What is a log All messages reported such as error messages and changes in the status are stored in a log Each message stored is timestamped and it is thus possible to determine the order of events from a log When the maximum number of messages in a log is attained a new message will replace the oldest one 3 2 What types of logs are there The following logs exist 14 4 User s Guide Name Common Operational System Hardware Motion Program Operator I O amp Communication User Arc Welding Spot Welding Internal 3 3 Viewing all logs e Choose View Log Max limit 40 20 20 20 20 20 20 20 20 20 20 20 Service Used to show All messages Changes in the status e g a change of operating mode The mes
193. be preloaded See Automatic loading of modules and programs on page 41 User s Guide 12 43 System Parameters 12 44 User s Guide System Parameters 6 Topic TeachPendant The following parameters are found under the TeachPendant topic Optional packages Defining customised file extensions Authorising and confirmation of user commands changing Pass Codes Activation of limited modpos function Programmable keys Default running mode settings e Choose Topics Teach Pendant The Most Common instruction pick lists and I O list are also stored when saving this topic 6 1 Defining Optional Packages If several process packages ArcWare SpotWare etc have been added to the system it is possible to define which package is to be used for the Program window and the Production window e Choose Topics TeachPendant e Choose Types Optional Package e Press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Description Use for Program The name of the process package to be used for Program or NONE if not used Use for Production The name of the process package to be used for Production or NONE if not used No process package available in this version 6 2 Defining File Extension It is possible to add file extensions for RAPID created files so that they are recognised by any file dialogue e Choose Topics TeachPendant e Choose Types
194. be read by people who will create programs edit programs etc This chapter explains some of the ways in which you can change the program you opened and started in the preceding chapters You will run the program step by step until you get to the position you want to modify modify this position change an argument in an instruction enter a new instruction position program a time delay WaitTime 13 1 Modifying positions 1 If you have exited the previous exercises choose the Program window see Figure 44 Figure 44 The Program window key The window in Figure 45 appears on the display File Edit View Special Program Test EXERCISE main Speed 75 Running Cycle 1 4 gt Move r v3200 fine tolo MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Start FWD BWD Modpos Instr gt Figure 45 The Program Test window User s Guide 4 43 Changing a Program Basic Operation the program the first instruction should be highlighted 2 Push in the enabling device and press FWD Move the robot to the first position in File Edit View Special Program Test EXERCISE main Speed 75 Running Cycle 1 4 gt lt Move N OO Fine Loold MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Start
195. binary coded using the indi vidual digital signals as a basis e Choose Topics IO Signals e Choose Types Groups All defined signal groups will be displayed see Figure 8 File Edit Topics Types Special System Parameters IO Signals Groups Name Unit Len Phsig 1 2 inport1l d327_11 4 5 outportl da327_11 6 9 Add Figure 8 System parameters of the type Groups e Select the signal group to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value 12 14 User s Guide System Parameters e Press OK to confirm To delete a signal group e Select the appropriate signal group e Press X Parameter Description Signal Name The name of the signal max 16 characters Unit Name The unit to which the signal is connected For more information about the unit type press the function key Info Signal Type The type of signal GI Group of input signals GO Group of output signals Group length The number of digital signals in the group The length must be set so that the group is within one unit The maximum value for length is 16 Start signal The physical channel of the unit to which the first signal the least significant is connected The remaining signals are auto matically connected to the following channels on the same unit Inverted Set to Yes if all signals in the group shall be inverted
196. bject You can create a new work object as follows e Press New You can change the values of a work object as follows e Press Change to input the value manually Define to use the robot to measure up the coordinate systems For more information see chapter 10 Calibration e Press OK to confirm The robot will move along the axes of the object coordinate system see Figure 18 X Figure 18 Linear movement in the object coordinate system 6 12 User s Guide Jogging 2 6 Jogging the robot along one of the world coordinate axes A e Set the keys uF v c to jog the robot in a straight line e Select the field Coord see Figure 19 e Press the function key World a i See eas Z 12 8 mm Q1 0 7071 Coord World Q2 0 0000 Tool tool0 Q3 0 0000 Wobj wobj0 Q4 0 7071 Joystick lock None xz y Incremental No vo World Base Tool Wobj Figure 19 Specify the coordinate system in the Jogging window The robot will move the TCP along the world coordinate axes see Figure 20 See a Figure 20 TCP movement is independent of the robot mounting 2 7 Using a stationary tool If a stationary TCP is active the work object will move in accordance with the chosen coordinate system User s Guide 6 13 Jogging 2 8 Jogging the robot axis by axis e Choose axis b
197. bodebeedesusstucsiyseseadsudesesensteevaceusebaces 8 60 14 1 Defining the Most Common instruction pick list eee eeeceeeeeeeneeeneeeees 8 60 14 2 Detault data global OC al nisinsin nasaia 8 61 14 3 Defining programming rule for robot positions eee eee eseeceteeeeeeeenees 8 62 9 The programming language RAPID csssccsscsscccsscceccssceeesscccees 9 1 1 Programming a POSITION ss esiscssoicssscrssessseessecssnceiccabnoushsscvseskssnysevescsouebecbbveusssssvsenes 9 3 1 1 Positioning instructions socce4 Sas gaeeuitiens Ges ssesde taboo seayuuasslwe ghey sateaeonseasgoassuentacsaseet 9 3 1 2 Programming an OUSEL assins oaas eaa EE TRE aS 9 6 2 Changing the Value of an Output eessecesccesoocssccssscessocesocesoosesosesocessocesocssoossso 9 7 oO VV AMUN MDG EEE caus vaca vane acaos ea E T eae Ree 9 8 3 1 WARIS for an TMD U ce sss tesa insaedtseug e suaadtan stats a es taaades 9 8 3 2 Waiting a specific amount Of time 4124224 ac eRe iets 9 10 4 Controlling the Program FlO0W eessoessocsssccssecesocesocesoocesocsssecesocesoosssosesoeessocesocse 9 10 AT Calling a SUbrOU LNG sneinen ee e o e RS 9 10 4 2 Program control within a routine sseseeeeseseeseesesssesreeseesresrrssresreserssreserseresee 9 11 5 Assigning a Value to Data Registers e ssesoossessocsooesessoesooesossoesoossosssssoossossses 9 14 10 Calibrati t sissi sssini noieses desea cccacsuessacsassdevens 10 1 1 Coordinate systems sses
198. box that appears When you have finished entering text press OK e Choose OK to confirm the save Note Ifa file with the same name already exists a warning will be given and you can choose to finish or continue Note If you have made a change in a system module you will be requested to save this alteration 7 2 Printing a program from the robot Print a whole program e Save the program on a diskette or the ramdisk and print out from the File Manager See Chapter 13 in this manual File Manager Print a module e Choose File Print The current module will be printed directly or saved to a file To be able to print a printer must be connected to the robot controller 7 3 Printing a program using a PC A program can be printed using a personal computer Most word processing programs can be used the only requirement being that the PC can support diskettes in DOS format e Store the program on a diskette e Load the program into the PC e Print the program If you do not wish to print out the position values of a position instruction save the program using the command File Print in the Program window and choose Save to file Only the current module will be saved 8 Changing the Program Programs can be protected against alteration by making the appropriate settings in the system parameters A password must then be used to make any changes See chapter 12 System parameters Topic Teach Pendant User s Guide 8 29 P
199. cation where to save the result e Choose OK to confirm the save If the estimated error is acceptable press OK to confirm the new track base frame not acceptable redefine by pressing Cancel e Choose File Restart in the Service window to activate the track base frame The definition is now complete but before proceeding with other tasks verify it by doing the following User s Guide 10 15 Calibration e Point out with the robot in coordinated mode the world fixed reference point with the track in different positions and print out the position in world coordinates Jog the track in coordinated mode 6 Coordinated external axes 6 1 How to get started with a coordinated moveable user coordinate system In the checklist below the steps required to coordinate a user coordinate system are described In each step there may be a reference to another chapter in this manual where more details of the specific actions to be taken will be found e Define the system parameters for the external mechanical unit see chapter 12 in this manual System Parameters Defining an external mechanical robot coordinated with the robot Find out the name of this mechanical unit and the corresponding logical axis e Calibrate the robot and the mechanical unit i e the zero position of the measuring sys tem for both robot and mechanical unit must be carefully determined See Calibration on page 6 e Define the base frame of the robot
200. ch Pendant e Choose Types Programmable Keys User s Guide System Parameters Now the definition of the keys will be displayed e Select the key to be defined and press Enter lt Parameter Description Key The designation of the key P1 P5 Type Type of key Input Output or None not activated Connection Name of signal to be chosen When Type is selected as Output the following are also available Key Pressed Defines how the output should be set Toggle if the signal value is high 1 it will become low 0 and vice versa Pulse a positive pulse 200 ms is generated Set1 Set0 either to high 1 or to low 0 Press Release the signal will be high 1 as long as the key is depressed When the key is released the signal will change to low 0 Allow in Auto Defines if the output should be possible to use even in automatic mode Yes allows the key to be operational in both manual and automatic mode No allows the key to be used only in manual mode When Type is selected as Input an event will be generated for this input This event can be related to System input The input must then be associated with a system activity see Defining input and output signals on page 12 Interrupt This is defined by the instruction ISignalDI see RAPID Reference Manual Waiting for input This is programmed via the instruction WaitDI but not Wait Until See RAPID Reference Manual 6 6 Defining Ru
201. chain is always tested at startup If the test failed an error message concerning enable will follow Check If enable chain test at startup failed the related error message will be Enable chain timeout 10070 Backup step ready The backup s is ready 10071 Backup error Error during the backup of s Ps Check Ps 10072 Restore step ready The restore s is ready User s Guide BaseWare OS 3 1 10073 Restore error Error during the restore of s s Check s 10074 NFS server up The connection to the NFS server s is working All devices remotely mounted from this server are now available 10075 NFS server down The connection to the NFS server s has been lost All devices remotely mounted from this server are unavailable 10080 Background task s has an older version of a module installed than the source s Check Restart the system with a P START to install the newer version 10081 Background task s failed to load a newer version of a module The source of the module is s Check See previous messages for the cause Or restart the system with a P START to load the newer version 10082 RAPID Task supervision Task s is not running the system will be set in SysFail state It s now impossible to change to motors on Ps Check See previous messages for the cause Restart the system to reset the error state User s Guide BaseWare OS 3 1 System and Err
202. chronized mechanical units is shown e Select the robot and press Enter or Def User s Guide 10 9 Calibration 10 10 A dialog like the one in Figure 4 will appear Robot Base Frame Definition Unit MASTER ROBOT Method 4 points Point Status 1 4 Point 1 Modified Point 2 Point 3 Point 4 Set ModPos Cancel OK Figure 4 Robot base frame definition dialog To choose a definition method Before you start modifying any positions make sure the desired method is displayed e Select the field Method and press Enter e Choose method for definition and press OK The method requires an elongator attached to the world fixed tip Input of world coordinates of the reference point e Press Set e Input the x y and z values e Verify that the input is correct and press OK To record world fixed reference points e Select the first point Point 1 e Jog the robot as close as possible to the world fixed tip e Modify the position by pressing the function key ModPos e Repeat the above for the points Point 2 to Point n To record the elongator X point e Select the elongator point Point X e Jog the robot as close as possible to the elongator point on the positive X axis e Modify the position by pressing the function key ModPos User s Guide Calibration To record the elongator Z point e Select the elongator point Point Z e Jog
203. cifies the time between two consecu tive polls NOTE All units produced by ABB Robotics Products except the gateway field bus units are event driven With these units the polling mechanism is used as heart beat only It is recom mended to use the default poll rate 1 second with these units 20 ms tol0 s resolution 10 ms Specifies that the I O unit will not be present on the bus at start up 3 2 Additional parameters for gateway field bus units A gateway unit is a unit which is connected to the internal BASE bus Can DeviceNet and also to an external field bus such as Interbus S Profibus A B RIO The gateway unit converts the data from one field bus to another field bus Allen Bradley Remote I O adapter DSQC 350 Unit Type d350 Parameter Rack Address Data Rate Description The rack address is entered in decimal form while Allen Brad ley use octal 0 7 Valid values are from 0 to 63 Allen Brad ley 0 77 Note that the Allen Bradley PLC series 2 30 starts from octal address 1 The data rate on the RIO Bus Valid values are 57 6 KBaud 115 2 KBaud 230 4 KBaud User s Guide System Parameters Starting Quarter The DSQC 350 starting quarter Valid values are First PLC value 0 Second 2 Third 4 Fourth 6 Rack Size The DSQC 350 rack size Valid values are 1 4rack 32 out 32 2 in 1 2 rack 64 out 6442 in 3 4 rack 96 out 9642 in fullrack 128 out 12842 in Last Rack Specifies that the
204. ck lock None xz y Incremental No y9 gt World Base Tool Wobj Figure 8 Specify the coordinate system in the Jogging window The tool that was last used when jogging the robot or last used for program execution is automatically chosen see Figure 9 User s Guide 6 7 Jogging X Figure 9 Linear movement in the tool coordinate system If you want to change the tool Select the field Tool see Figure 10 Coord Tool Q2 0 0000 Tool gun Q3 0 0000 Wobj wobj0 Q4 0 7071 Joystick lock None xz y Incremental No v9 gt Figure 10 Choose a tool by selecting the field Tool e Press Enter lt e Select the desired tool from the dialog box which subsequently appears on the display Tool0 in the dialog box corresponds to the centre of the mounting flange Select desired data in the list 1 2 gunl gun2 gun3 tool0 tooll New Change Define Cancel OK Figure 11 Changing or adding a tool You can create a new tool as follows e Press New You can change the values of a tool as follows 6 8 User s Guide Jogging e Press Change to input the value manually Define to use the robot to measure up the tool coordinate system For more information see Chapter 10 Calibration e Press OK to confirm 2 3 Reorienting the tool er Q e Set the
205. command will be carried out However as it has three dots after it the command will not be performed directly since more information is required You must now in this case choose the particular program you wish to open A e l l z Figure 29 The Enter key on the teach pendant User s Guide 4 27 Selecting a Program Basic Operation Using the Unit function key you can switch between the robot s internal memory ram 1disk the diskette unit flp1 or some other type of mass storage device 6 Press Unit Check that flp1 appears after Massmemory unit A dialog box will appear and the contents of the diskette will be shown as in Figure 30 Open Select a Program or a Module i Massmemory assmemory unit flpl q The training pro name gram is stored here 15 DEMO Directory MOVEPROG Directory The appearance of README Program a l 3 SERVICE Directory the list can vary SYSPAR Directory Unit Cancel OK Figure 30 The Open dialog box If a dialog box does not have any menus is closed by pressing Cancel the command requested will not be carried out If you press OK the command requested will be car ried out and the dialog box will close 7 Select DEMO Move the cursor with the Up and Down arrow keys 8 Press Enter 9 Select EXERCISE 10 Press OK and a window like the one in Figure 31 will appear File
206. cordance with appli cable safety regulations Care must be taken at all times 10 Risks during Installation and Service To prevent injuries and damage during the installation of the robot system the regula tions applicable in the country concerned and the instructions of ABB Robotics must be complied with Special attention must be paid to the following points e The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function e The instructions in the Product Manual nstallation must always be followed e The mains supply to the robot must be connected in such a way that it can be turned off outside the robot s working space User s Guide 3 11 Safety e The supplier of the complete system must ensure that all circuits used in the emer gency stop function are interlocked in a safe manner in accordance with the applica ble standards for the emergency stop function e Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly e Safety zones which have to be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices e Turntables or the like should be used to keep the operator away from the robot s work ing space e Those in charge of operations must make sure that safety instructions are av
207. d Actual d Check 1 Change vendor id in configuration 2 or check module 71091 Invalid unit type DescriptionReason The profile read from unit s doesn t match value in unit type configuration Configuration d Actual d Check 1 Change profile in configuration 2 Check that the type of board is correct 71092 Invalid unit type DescriptionReason The product code read from unit s doesn t match value in unit type configuration Configuration d Actual d Check 1 Change product code in configuration 2 or check module 71093 Invalid unit type DescriptionReason The major revision read from unit s doesn t match value in unit type configuration Configuration d Actual d Check 1 Change major revision 2 or check module 71094 Too many cross actors def DescriptionReason The cross connection has too many From signals s Check 1 Check the cross configuration User s Guide BaseWare OS 3 1 System and Error Messages 71095 Too long cross actor str DescriptionReason The From part in the cross string is too long s Check 1 Check the cross configuration 71097 Parameter store error DescriptionReason Signal s This type of signal can t have store option Check 1 Only digital output signals can have store 71098 NFS server lost DescriptionReason The contact with the NFS server s was lost Check 1 Check the NF
208. d Testing Arguments can be specified as numeric values e g string values e g Waiting for machine data e g reg2 function calls e g Abs reg2 expressions e g reg2 reg3 5 4 4 Getting more information about an instruction e Select the desired instruction and press Enter The dialog box shows the names of the arguments see Figure 10 Current Instruction 2 5 MoveL ToPoint robtarget Argument Speed v500 speeddata lt Data type name Zone fine zonedata Tool tool tooldata Value 4 Change Info OptArg Cancel OK Figure 10 The name value and data type of each argument is displayed e If you wish to change an argument choose Change or press Enter See Changing an argument on page 33 for more information e If you wish to add or remove an optional argument choose OptArg See Adding optional arguments on page 34 for more information e Choose OK to exit the dialog 5 Programming In this chapter you will find descriptions for general handling of the various instructions in a program moving copying or adding For details about programming the most common instructions please see the next chapter in this manual 9 The programming language RAPID For other instructions see the RAPID Reference Manual 8 14 User s Guide Programming and Testing 5 1 Choosing from the instruction pick list You can choose in
209. d and heavy external axes or when interpolation close to singularity Check Split segments with long interpolation time path_resolution 4 minutes or change to joint interpolation or move position away from singularity 50172 MoveJ not allowed MoveJ not allowed with work object coordinated with external position mechanical unit Check Change interpolation mode or work object 50173 Use fine point Use fine point when changing tool or work object coordination when work object is coordinated with external pos mechanical unit Check Create a fine point and then change the tool 50174 WObj not connected The WObj is not connected to the moving conveyor Robot TCP cannot be coordinated to work object Check Check for missing WaitWObj Check for DropW Obj occuring before end of coordination 50175 Conveyor moving Conveyor moving while attempt to coordinate robot TCP to conveyor work object while in prohibited mode Check It is not possible to coordinate to conveyor while in Manual Reduced Speed or stepping in Auto and the conveyor is moving 16 83 System and Error Messages 50176 Conveyor not active Conveyor mechanical unit was not active when attempt to coordinate robot TCP to conveyor work object Check Make sure conveyor mechanical unit is active Check for fine point for last coordinated motion before DeactUnit 50177 Unable to restart Conveyor moving while attempting to re
210. d service routine without parameters can be executed without losing the call hierarchy and program settings e g program displacement mechanical unit activation etc e Choose Special Call Service Routine A dialog box appears displaying all possible service routines e Select the desired service routine and press OK When the program pointer reaches the end of a called service routine you are asked whether to run the service routine again or to return to the original program pointer where the Call Service Routine was performed To go to a position without moving the program pointer Place the cursor on the position argument in the instruction You can also select a position robtarget in the Program Data window e Choose Special Go to selected position A dialog box appears see Figure 23 p Start robot movement towards selected position Start Cancel Figure 23 The Go to selected position dialog box e Press the function key Start to start the movement 6 8 Simulating wait conditions When the robot is stationary in a wait instruction e g WaitDI dil or WaitTime 3 a dialog box is automatically displayed User s Guide 8 27 Programming and Testing To continue in the program without fulfilling the condition or time press Enter The dialog box will disappear automatically when the condition has been fulfilled 7 Saving and Printing Programs 7 1 Saving the program on diskett
211. de by pressing the enabling device on the be teach pendant halfway in o If the enabling device is released and pressed again within half a second the robot will not return to the MOTORS ON state If this happens first release the enabling S device then push it halfway in again User s Guide 5 5 Starting up 5 Emergency Stops 5 1 Activating the emergency stop button Emergency stop buttons are located on the operator s panel and on the teach pendant There are often other ways of activating an emergency stop but these depend on the robot installa tion When the emergency stop button is activated the power supply to the motors is shut off and program execution stops 5 2 Resetting after an emergency stop e Fix the problem that caused the emergency stop e Reset the emergency stop state by pressing the MOTORS ON button see Figure 3 n 2 Figure 3 The emergency stop must be reset before setting the robot in the MOTOR ON state MOTORS ON button AN 5 6 User s Guide Starting up 6 The Teach Pendant The teach pendant is described below see Figure 4 jJ Hold to run O Enabling a device Joystick Emergency stop button Display Figure 4 The teach pendant is used to operate the robot PN Jogging Used to jog the robot Program Used to program and test Inputs Outputs Used to manually operate the input and output si
212. de selection using the operating mode selector The applicable safety requirements for using robots laid down in accordance with ISO DIS 10218 are characterised by different modes selected by means of control devices and with clear cut positions One automatic and two manual modes are available AN Manual mode lt 250 mm s max speed is 250mm s 100 full speed O Automatic mode The robot can be operated via a remote control device The manual mode lt 250 mm s or 100 must be selected whenever anyone enters the robot s safeguarded space The robot must be operated using the teach pendant and if 100 is selected using Hold to run control In automatic mode the operating mode selector is switched to Q and all safety arrangements such as doors gates light curtains light beams and sensitive mats etc are active No one may enter the robot s safeguarded space All controls such as emer gency stops the control panel and control cabinet must be easily accessible from out side the safeguarded space Programming and testing at reduced speed Robot movements at reduced speed can be carried out as follows e Set the operating mode selector to lt 250 mm s e Programs can only be started using the teach pendant with the enabling device acti vated The automatic mode safeguarded space stop AS function is not active in this mode User s Guide 3 7 Safety Testing at full speed Robot movements at programmed sp
213. de working area Check Check the work object Check the joint working range Move the joint in joint coordinates 50052 Joint speed error The speed of joint s is too high relative the ordered speed Check 1 Check the tune parameters external forces on the joint and hardware 2 Reduce programmed speed 50053 Revolution counter error Too big difference between the counter in the serial measurement board and the expected value in the robot computer for joint s Check Update the revolution counter Replace serial measurement board 50055 Joint load error Actual torque on joint s too high May be caused by incorrect load data too high acceleration high external process forces low temperature or hardware error Check 1 Check load data 2 Reduce acceleration or speed 3 Check hardware 50056 Joint collision error Actual torque on joint s is higher than ordered while at low or zero speed Check May be caused by jam error the arm has got stuck or hardware error 50057 Joint sync error The position of joint s after power down failure is too far away from the position before the power down failure Check Make a new update of the revo lution counter 16 78 50058 Tool coord sys error The z direction of the tool coordinate system is almost parallel with the path direction Check Change the tool coordinate system to achieve at least 3 degrees deviation between z direction
214. default behaviour Average size in bytes of one PERSISTENT variable This setting will affect the maximum number of persistents in the system User s Guide System Parameters 5 6 Automatic loading of modules and programs System modules and or normal RAPID program modules can be loaded automatically when the robot is powered on restarted Changes to any item in this menu will force the system to restart the program handling part of the system at the next warm start All user programs will be erased and all task modules specified in the configuration will be reloaded e Choose Types Task modules A list of the files which will be preloaded will be shown see Figure 20 File Edit Topics Types System Parameters Controller Task modules Task File 1 6 MAIN ramldisk base sys MAIN ramldisk user sys SUPERVISION ramldisk base_mt sy SUPERVISION ramldisk superv mod GUN ramldisk base_mt sy GUN ramldisk gun mod Add Figure 20 Programs loaded into the system during the warm start sequence e Select the item to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value e Press OK to confirm Parameter Description Task The symbolic name of the task to which the module should be loaded The available task s is shown under the type Tasks See Defining multitasking on page 42 File A path to the module file Note The fi
215. defined work area are larger than max allowed area 50215 Load identification error Axis d will move outside working range Check Move the axis to a position further from the working range limit Operator error messages 60001 s missing Tool s is not used in current program Maybe because it has been deleted or it is not defined Check Change to another tool using the Jogging window User s Guide Base Ware OS 3 1 60002 s missing Wobj s is not used in current program Maybe because it has been deleted or it is not defined Check Change to another workobject using the Jogging window 60003 Directory not created The directory s cannot be created Probably because directory already exists or the disk is write protected Check Check if directory exists or if disk is write protected Check also if space on disk is enough 60004 Robot Hold confusion The used tool and the used work object cannot both at the same time be held by robot or be stationary Check Check the robhold component of the used tool and work object 60005 s missing The workobject s contains a coordinated mechanical unit which cannot be found Check Check the mechanical unit component of the workobject 60006 s Userframe The workobject s contains a coordinated mechanical unit which has no defined userframe Check Check the mechanical unit component of the workobject 60007 Jo
216. desenssdeenesense 7 7 3 1 To display information on a given Signal ceecceceeeeecseeceeeeeeeeeeeeeesneeeesaes 7 7 3 2 To display a chart of all digital signals of a unit eee este eeeeeeeeeees 7 7 9 0 20 pintan VO MSU acccsicectancec ccleetatecctaates canes aecduuaive conta a amet e 7 8 8 Programming and Testing cccssssssccccsssssssssccsccsssssssccsscsssssssssssssees 8 1 1 Creating a New Progr aii cs cass sess cass cceecccss taivacenseunscvs caectevaxcopnans sevectusueonacapevsnacsvyenecs 8 5 he ES WHAE IS A PEO STAIN cciias a tueedeenideaeameuccteate a ase 8 5 I 2 The POST ANN WOW cee ie Cs ae et SU ca 8 6 1 3 Creating a new program senesinin ss sidedatasughadeoavedcatanseeancncebedetanens 8 6 14 Loading an existing progranta iseccaiitenieienie einen dna gen 8 7 2 Defining Tools and Work Object cscccssssccssssscsssscssssscssssscsssscsssecssssessesees 8 7 3 Creating New Routine cs ssssecscoccssececsseeesseccsssencnssseensssnsnsusnsuveonessteenevenreesstsszeseasosys 8 8 3 1 Whatis a toutte ite ect etd eee ve eeiieeet en einai ree eee 8 8 3 2 The Program Routines Window iiccoiucs fs ucts ash dathaaitlen atte dite Ruts ee lene 8 9 5 SATE ARNG a eW TOUTING nincsen nie iene chaaas cvyana wets E data eat avy ORs 8 10 34 D plicatng She LN oa SS ye sau aes cstv a ee Succ stone vas cot ce AAi 8 11 4 Creating new instructions sseesseescoesooccsscessecesocesooesoocssoecssecesocesoosesosessecssocesocse 8 12
217. do3 amp do61 User s Guide System Parameters In Configuration file EIO_CROSS Lres doll Lact di2 amp do3 Lresdol4 Lact dil2 amp do3 Lres dill do23 dol7 Lact dil3 amp do3 Lresdol5 Lact doll dol4 dill Lres do33 Lact dill amp do23 Lres do61 Lact dol7 amp do3 Lres do54 Lact dol5 do33 Calculation of number of cross connections If you make a cross connection with logical conditions the number of cross connec tions may be more than the number of signals actual used in the cross connection itself You will use one cross connection for each input to a gate and one for the output of the gate If you connect an output from one gate to an input of another gate it takes two cross connections even if there is only one signal involved In the configuration above you have 15 signal names used but it takes 24 cross con nections 3 6 List all available I O Unit Types e Choose Topics IO Signals e Choose Types Unit Types All available unit types will be displayed as shown in Figure 10 File Edit Topics Types System Parameters IO Signals Unit Types Name Product Name 7 8 eip000 Simulated d320 120 Vac Unit d327 Combi Unit d328 24 Vdc Unit d331 Panel Unit d332 Relay Unit d350 RIO Adapter Figure 10 List of all available unit types To get detailed information about a particular unit type e Select the appropriate unit type and
218. dow is not available the screen display window will be dis played automatically and the controller will need to be restarted in manual mode to return to the screen options window 14 The Screen Loading 15 16 A user screen package file can be loaded via the screen loading window The file will be loaded analysed and installed as a new user screen package e Press Load in the screen options window A dialog box appears displaying all user screen package files as a parameter file in the current directory see Figure 8 User s Guide Screen Viewer New screen package loading Select the screen package to load 1 3 pa Go up 1 level SWSCREEN Parameters AWSCREEN Parameters Unit Cancel OK Figure 8 The screen loading window If necessary change the mass storage unit by pressing the function key Unit until the cor rect unit is displayed To load user screen package files from a diskette choose flp1 e Select the directory from which the user screen package files are to be loaded You can move to the next directory level by selecting the desired directory or upwards and pressing Enter e Choose OK to confirm the load An alert box will be displayed after reading with the state of the loading After this the display returns to the screen options window 15 The Screen Information e Press Info in the screen options window A dialog box appears displaying t
219. drive unit joint s Check Allow motor to cool down Check replace External Drive Unit See documentation for Atlas DMC FBU 16 48 39303 External Drive Error High Power device temperature on external drive unit joint s Check Allow drive unit to cool down Check replace External Drive Unit See documentation for Atlas DMC FBU 39304 External Drive Error Current regulator fault detected on external drive unit joint s Check See documentation for Atlas DMC FBU Check replace External Drive Unit 39305 External Drive Error Short circuit detected on drive unit joint s Check See documentation for Atlas DMC FBU Check replace External Drive Unit 39306 External Drive Error Missing ENABLE for external drive unit joint s Check See documentation for Atlas DMC FBU 39307 External Drive Error External drive unit joint s has performed a CPU reset Check Restart the system See documentation for Atlas DMC FBU Check replace External Drive Unit 39308 External Drive Error Too many consecutive communication errors on external drive unit joint s Check Restart start controller Replace drive unit Replace drive unit right to the one reporting the error Replace Robot Computer Board User s Guide Base Ware OS 3 1 39309 External Drive Error Too many consecutive synchronization errors on external drive unit joint s Check Restart start controll
220. e User s Guide 10 11 Calibration If the estimated error is acceptable press OK to confirm the new robot base frame not acceptable redefine by pressing Cancel e Choose File Restart in the Service window to activate the base frame The definition is now complete but before proceeding with other tasks verify it by jogging the robot in the world coordinate system 5 Coordinated track motion 5 1 How to get started with a coordinated track motion 10 12 In the checklist below the steps required to coordinate track motion are described In each step there may be a reference to another chapter in this manual where more details of the specific actions to be taken will be found e Define the system parameters for the track motion see chapter 12 in this manual Sys tem Parameters Defining a track motion with coordinated motion Find out the name of this mechanical unit and the corresponding logical axis e Calibrate the robot and the track motion i e the zero position of the measuring system for both robot and track must be carefully determined See Calibration on page 6 e Define the base frame of the robot see Defining the Base Frame for the Robot on page 9 Please observe that the track must be in its calibration position when the robot base frame is defined e Define the base frame of the track see Defining the Base Frame for a track motion on page 12 e Store all these definitions on a diskette by giving
221. e Using a printer e Connect the printer channels to the test outputs in the cabinet The outputs are marked 1 and 2 with a common zero point ground Voltage level 10V Required a two channel printer chart recorder 25 135 mm s e g Brush 220 Inputs X5 TSTOUT1 X6 TSTOUT2 X7 0V X8 0V e Make sure that the external axis is commutated and calibrated Any position may be defined as the calibration position User s Guide 12 71 System Parameters 12 72 e Tune the axis so it may be jogged without stopping due to speed or torque supervision Keep the same values of Kp and Kv as above but multiply Ti by a factor of 2 Ti will be re tuned last in the procedure e Program a back and forth motion of the external axes with test signals enabled For the final tuning of the control parameters of the axis it is convenient to use the TuneServo command The following program may be used as an example STN1 is the name of the external axis PROC main ActUnit STN1 TestSign 1 speed STN1 1 1 0 TestSign 2 torque_ref STN1 1 8 0 TuneServo STN1 1 TuneValue Type TUNE_KP TuneServo STN1 1 TuneValue Type TUNE_KYV TuneServo STN1 1 TuneValue Type TUNE_TI FOR i FROM 1 TO 10 DO MoveJ t1 v_tune fine too 10 Move t2 v_tune fine too 10 ENDFOR DeactUnit STN1 ENDPROC The velocity data and test positions can be modified depending to the value that is to be tuned TestSign Output SignalId MechUnit Axis Scale Stime
222. e variable Global In Module USER 1 1 reg7 0 num Cancel OK Figure 42 A data declaration includes the name and characteristics of the data e Select the appropriate field and specify the desired characteristics by pressing Enter and specifying the desired alternative in the dialog box that appears fields marked with choosing an alternative using the function keys fields marked with 7 specifying the value directly using the numeric keyboard numeric initial value Field Name Type Global Local In Module Initial value Description The name of the data a maximum of 16 characters Specifies whether the data is to be a constant Const variable Var or persistent variable Pers Specifies the scope attribute for the data Default for the datatype is set in File Preferences See Default data Global Local on page 61 The module in which the new data will be used A value assigned to the data when e g reading from a diskette Change the value by pressing and enter the new initial value e Choose OK to approve the definition Tip Itis sometimes easier to create new data by duplicating and changing existing data 10 4 Creating new array data e Open the Program Data window by choosing View Data The Program Data window is opened and displays all data of the type last selec
223. e 37 Displacement frame definition dialog The status can be defined as follows Status Meaning No position defined Modified Position modified User s Guide Calibration To choose the definition method Before you start modifying any positions make sure the n point method together with the number of points that you want to use is displayed e Select the field Method and press Enter e Enter the desired number of points and press OK To record the Initial Points e Select the first definition point Initial Point 1 e Jog the robot as close as possible to a well defined position on the object e Modify the position by pressing the function key ModPos e Repeat the above for the points Initial Point 2 Initial Point 3 etc To record Moved Points e Move the object to its new position e Select the first definition point Moved Point 1 e Jog the robot as close as possible to the same position on the object as for Initial Point 1 e Modify the position by pressing the function key ModPos e Repeat the above for the points Moved Point 2 Moved Point 3 etc To calculate the displacement frame e Press OK to calculate the displacement frame When the calculation is finished a dialog like the one shown in Figure 38 will appear Displacement Frame Calculation Result Disp disp4 Orig 1050 51 1000 00 1231 82 Calculation Log 1 4 Method n points n 3 Mean error 4 12 Ma
224. e 61 Dimension Size of the chosen dimensions In Module The module in which the new data will be stored Initial value A value assigned to the data when e g reading from a diskette Change the value by pressing and enter the new initial value e Choose OK to approve the definition or Cancel to abort the definition User s Guide 8 49 Programming and Testing 10 5 Duplicating data e Open the window Program Data by choosing View Data e Select the data to be duplicated e Press the function key Dupl e Specify the new name in the dialog box that appears e Choose OK to confirm the duplication 10 6 Storing position data using the robot e Open the Jogging window and specify the tool and work object on which the position is to be based e Jog the robot to the desired position e Create new data as described in Creating Data on page 45 Specify the data type robtarget The current position of the robot will be automatically stored as an initial value 10 7 Routine data Normally data program data can be accessed from anywhere in the program Data can also be linked to a specific routine routine data and in this case exists locally within the routine e Open the Program Data window by choosing View Data e Choose Data In Routine The window will then display the routine data for the current routine The window is identical to the window shown in Figure 39 except that it displays the routi
225. e NOT operator is bool Check the type of the operand 40034 Type error Task 16s Illegal type 18s for left operand of OR XOR or AND operator Check The only allowed type for the operands of the OR XOR and AND operator is bool Check the type of the operand 40035 Type error Task 16s Illegal type 18s for right operand of OR XOR or AND operator Check The only allowed type for the operands of the OR XOR and AND operator is bool Check the type of the operand User s Guide Base Ware OS 3 1 40036 Type error Task 16s Incorrect number of indices in index list for array 18s with i dimension s Check Make sure that the number of indices in the index list is the same as the number of dimensions of the indexed data array 40037 Data declaration error Task 16s LOCAL illegal in routine constant declaration Check Only program data declarations may have the LOCAL attribute Remove the LOCAL attribute or move the declaration outside of the routine 40038 Data declaration error Task 16s LOCAL illegal in routine variable declaration Check Only program data declarations may have the LOCAL attribute Remove the LOCAL attribute or move the declaration outside of the routine 40039 Name error Task 16s Constant name 16s ambiguous Check Routine data must have names that are unique within the ro
226. e down rot side Base coordinate system when using stationary tool St tool tool down rot side Tool coordinate system when using stationary tool St tool wobj down rot side Object coordinate system when using stationary tool Axis by axis jogging e Specify the desired axis direction for the respective joystick movements as shown in Figure 33 1 for axes 1 and 4 2 for axes 2 and 5 3 for axes 3 and 6 The signs denote a positive or negative direction of the motion for a positive joystick deflection Parameters Description Group 1 down rot side Axis joint 1 2 and 3 Group 2 down rot side Axis joint 4 5 and 6 7 20 Defining the joystick directions for a single external axis These values are available under the System Parameters window e Load the jog direction template file SINGLE CFG for single external axes See Loading parameters from a diskette or some other mass storage device on page 7 Use the command File Add New parameters The file can be found on the CONTROLLER PARAMETER diskette under directory JOGDIR Loading this file will define the parameter instance name strings x1 x2 KB XA x5 and x6 User s Guide System Parameters When joystick directions for several mechanical units are to be defined the template files for all the units can be loaded here When the file has been loaded perform a Restart e Choose Topics Manipulator e Choose Types 1 Single e Select single
227. e from other modules or Local only reachable in the module where the data is declared When new data are created the setting in this list will be used for the data scope attribute e Choose File Preferences e Select Default data Global Local and press Enter e A list with all available datatypes are presented Mark the datatype you want to change and press Global or Local Note This definition is stored in the system parameters topic Teach Pendant which should be saved from the System Parameters window For more information regarding Global and local data see RAPID Reference Manual User s Guide 8 61 Programming and Testing 14 3 Defining programming rule for robot positions It is possible to select whether or not to automatically create new robtargets when programming move instructions Automatic name sequence When a Move instruction is programmed a new robtarget is automatically created If the last used ToPoint was named i e not a a new robtarget will be created and named according to a sequential naming rule For example p10 p20 p30 or p12 p13 p14 etc Dialog with next robtarget selected This rule is used when robtargets are created in advance When a Move instruction is programmed no robtarget is created Instead the instruction argument dialog is opened with the next sequential robtarget selected For example if the last used robtarget was p100 the instruction argument dialog will b
228. e function key Cont or Cycle Use the key to select the lower part of the window Use the function key Start to start program execution in the mode that you chose above To step the program forwards backwards use the function keys FWD and BWD see Figure 21 User s Guide 8 23 Programming and Testing Program Test WELDPIPE main Speed 50 Running Continuous 1 26 Init data counter 0 Go to start position MoveL pstart v500 FINE gripper WaitUntil dil 1 Start Set startsignal open_gripper Start FWD BWD Modpos Instr Continuous or cycle Step by step backwards Step by step forwards Figure 21 A program can be run in several different program execution modes Instructions act differently during step by step execution than during continuous execution The principal differences are as follows Positioning instructions are executed in the normal way but the robot gets into position even when a fly by point is programmed Other instructions execute in the normal way when executing forwards and are skipped when executing backwards 6 5 Starting program execution A 8 24 e Choose the speed correction as above e Select the lower part of the window by pressing the List 12 key if it is not already selected When you start program execution the robot will start to move Pe
229. e ie a i E a E E E E T ERE 3 2 Applicable Safety Standards eseoessoesssessocesocesoocsssecssocesocesoosssocessecssocesocesoocessesssecssoess 3 3 Fir Egytinguis hinf sssssissssssssscsssscovosssstessssossasssossssassossetessds op ss vasuasbenaluassivucnsessscbeatinussvectins 4 4 Definitions of Safety Functions sesssesssessocesooessocessecssocesocesoosssocessecssocesocssoocessessseeesoeee 4 5 Safe Working Procedures eessecesoseccoccsoossooecoscccocsooocsococsocecosscsoesosoesssoccosecoosesoessosessesee 5 5 1 Nominal Operations ee ororo e ea a a e at a Sa aSa 5 6 Programming Testing and Servicing sessscsssecssecssocesocesoocesoecssccesocesoosssocesocessocesooseo 5 TARAA DETIT nI 1ER E AE AT ET EEATT 6 7 1 The safety control chain of operation e eeseseseesesseeerssresseesesreeserseesressreseeseeesresee 6 T2 Emergency stops enire e a E E E E E gees 7 7 3 Mode selection using the operating mode selector eeeeeseeseeeeeseerrsressrrerrsresse 7 TA Enabling deyic sn srine a E e E E EE senses 8 To Hold to r m Control scissa a a E RE a 8 7 6 General Mode Safeguarded Stop GS connection sessessssseessesssessseresseeessee 9 7 7 Automatic Mode Safeguarded Stop AS connection 0 0 eee eeteceeeeeeeeeeeeeeeeeens 10 7 8 Limiting the working space siiaveccessisevacccsisicvedeatecouacalesgeesassavaaedsgusndeausavesvebedsecenaeats 10 TO Supplementary PUNCUOus sonno ae Bidets es eee Bdge eee eee i 10 8 Safety
230. e list is used when you want to create new data and refer to it If you choose New you define new data as described in Creating Data on page 45 by choosing a function press the function key Func and select the desired alternative from the list A new dialog box that can be used to program arguments appears like the one in Figure 12 Specify the function argument in the same way as you specified the instruction argument Use the function key Skip to delete optional arguments that are not to be included by entering an expression by pressing More For more information see Programming an expression on page 19 e Choose Next to change the next argument e Choose OK to confirm Optional arguments that are not included at the start can be inserted see Adding optional arguments on page 34 The structure of an IF FOR or TEST instruction can be changed see Changing the structure of an IF FOR or TEST instruction on page 35 User s Guide 8 17 Programming and Testing 5 3 Expressions What is an expression An expression is used as an argument of an instruction and can have an arbitrary number of components There are three different types of expressions hae logical expressions these have the value true false and are used together with tests e g IF regl 5 AND reg2 gt 10 IF dil 1 arithmetic expressions these have a numeric value and are used together with calculations e g regl reg2 3
231. e opened with p 0 selected Dialog with selected Same as Dialog with next robtarget selected except that the instruction argument dialog is opened with the selected e Choose File Preferences Select Robtarget programming rule e Select a programming rule and press OK 8 62 User s Guide The programming language RAPID CONTENTS Page 1 Programming a Position si syssstesinscscessesaucancassewedoensiacendsautandessanesnsacaedsensucdansessabanesboantionsaes 3 11 Positioning IMStrucnOns 524 4i asiet easels ees eee As 3 1 2 Programming anm OES EL te ce iat oa dct ea et toes ee tee Aa iota ak ed Monsen tin tate Laas 6 2 Changing the Value of an Output ccscccssscsssssssssssssssrssssssecssssesssssccssssecssasecsnssecsssseces 7 3 WANO 5 5 2 sec coccass tess esics ccs puss sedans oseseenc pane du yess weeens ous ans aias IESSE Sostoa oeii oao ssaa eo reas sri o eisa dost rias 8 Sal Watne foran INDUE aie i a E Ea A EE ie 8 3 2 Waiting a specific amount of time eseesseeeseseeseeseesseseresresreseresresseserssrensessrereresesee 10 4 Controlling the Program PLOW eseoessoeesscsscocesooessocessecssocesocesoosssocsssecssocesocesooesssesssecesosee 10 4 1 Calling a subroutines secerni ten terna e i aE AEEA E Eii 10 4 2 Program control within a routine esesssseseeseseseeeeesersersrresresseserestessessresressessresees 11 5 Assigning a Value to Data Registers seeesccescocsssecssocescocssoosesocessec
232. e or some other type of mass memory To save a program that has been stored previously e Choose File Save Program The program is duplicated to mass memory and replaces the version that was last saved If the file name or module name is not the same the dialog Save Program As will be displayed automatically To save under a new name e Choose File Save Program As A dialog box appears displaying all programs in the current directory see Figure 24 SSS Save Program As Name WELDPIPE Mass memory unit Massmemory unit flp1 ROBOT1 e 7 1 5 Directory level Rae Go up 1 level WELD1 Program WELD2 Program WELDPIPE Program TEST Directory Unit New Dir Cancel OK Figure 24 The dialog box used to store programs e If necessary change the mass memory unit by pressing Unit until the correct unit is displayed If the program is to be saved in another directory e Select the lower part of the window by pressing the List key e Choose the directory in which the program is to be saved Move up or down in the directory by choosing either up or the desired directory down and press Enter e Select the upper part of the window by pressing the List key 8 28 User s Guide Programming and Testing e Press Enter when the field Name is selected e Specify the new name in the dialog
233. e parameter into an optional parameter or change the data type of the parameter If the object is not a parameter change the data type 40101 Type error Task 16s Type mismatch of expected type 18s and type 18s Check The expression is not of the expected data type User s Guide Base Ware OS 3 1 40102 Type error Task 16s Type mismatch of aggregate expected type 18s Check The aggregate does not match the expected data type 40103 Type error Task 16s Persistent 18s 16s type mismatch Check There is already a persistent data with the same name but with another data type Rename the persistent or change its data type 40104 Data declaration error Task 16s Cannot determine array dimensions circular constant references Check Check that any referred constants are correctly defined If so the program is too complex Try to rewrite the declarations 40105 Data declaration error Task 16s Cannot determine type of constant value circular constant references 7 Check Check that any referred constants are correctly defined If so the program is too complex Try to rewrite the declarations 40106 Data declaration error Task 16s Cannot evaluate constant value expression circular constant references 7 Check Check that any referred constants are correctly defined If so the program is too complex Try to rewrite the declarations User s Guide B
234. e to 5 Volt regulator in Powersource Control Unit has been down Check Indicates that there is a problem in power supply but the function is probably not affected Check incoming power supply to Powersource Control Unit User s Guide BaseWare OS 3 1 System and Error Messages 117205 Welding equipment error High DC inverter bus voltage Hardware will shut down inverter till voltage comes down to normal Check Might be caused by high mains impedance or transients possible to restart welding as soon as voltage has dropped below limit 117206 Welding equipment error Temperature in power source heatsink too high Inverter is shut down until temperature switch is closed again Check Ensure that there is no obstacle that reduces the cooling airflow that passes through the heatsink of the powersource Wait until temperature switch is closed 117207 Welding equipment error High current in inverter circuit Might be caused by component failure Check Reset welding equipment with power switch Check that the power source does not consume unnormal high current without start command If so there is a component failure 117208 Welding equipment error PCB supply voltage 15VC on Powersource Control Unit to high or to low Check Replace Powersource Control Unit 117209 Welding equipment error PCB supply voltage 15V on Powersource Control Unit to high or to low Check Replace Powersource Control Unit
235. e work object as was originally used when defining the robtarget data and which was used as a parameter in the movement instructions If no work object was used the wobjO should be stated Mirroring of orientation The orientation of the robtarget position is also mirrored This mirroring of the orientation can be done in two different ways where either the x and z axes are mirrored or the y and z axes see Figure 35 The method used x or y axis the z axis is always mirrored is dependent on the tool used and how the tool coordinate system is defined In the mirror dialogue the method must be stated 8 40 User s Guide Programming and Testing Y y Mirroring of x and z axes oN f s Mirroring of y and z axes Figure 35 Two different ways of mirroring Configuration The configuration will not be mirrored which means that after mirroring it has to be carefully checked by executing the path in test mode If the configuration has to be changed this must be done manually and the position corrected with a modpos command User s Guide 8 41 Programming and Testing 8 42 Mirror example 1 one robot A programmed routine org is stored in the robot s memory A mirrored copy of this routine is to be created and stored with the name mir in memory All positions are related to the work object wobj3 The mirror plane is known from three positions in the plane p1 p2 and p3 An original position
236. ears and you will be asked whether you want to save the old program or not Tip If there is an error in the program this error will be displayed if you choose File Check Program Note When a program is loaded into the robot it requires about three times as much memory compared with the size of the file on diskette 2 Defining Tools and Work Object Before starting any programming work it is essential that you define the tools work objects and other coordinate systems that you intend to use The more accurately you do this the better the results you will obtain See Chapter 10 Calibration User s Guide 8 7 Programming and Testing 3 Creating New Routines 3 1 What is a routine Before you start to program you should think out the structure of your program The program should be divided into several subroutines to get a more readable program Instruction sequences that recur frequently in the program such as gripper handling form their own routines Figure 3 illustrates an example of a simple program the robot takes parts to and from a machine Figure 4 illustrates the structure of this program Machine In feeder Out feeder Figure 3 The robot gives a part to a machine which then processes it First the robot fetches a part from the In feeder and places it in the machine where the part is processed Then when this has been done the robot takes the part and places it on the
237. ecific user screen package installed see the documentation given with this user screen package 15 18 User s Guide Error Management CONTENTS Page 1 Error Mama Senet vasicicsiesdetiscdinsstacadescisnaendetadewinsiaatendedascniusasncancesscusaneeewaseuticcbeacctne 3 1 1 Confirming an error Message 1 255 400 eA aa aie eae 3 1 2 Calling up suggestions on how to correct an CLTOL eee eeeeeeeeeeneeeneeeeeeeeeee 3 1 3 Acknowledging warning messages ce eesceseeeseeeseeceaeceseeeseeeeaeecsaeenseenees 4 User s Guide 16 19 Error Management 16 20 User s Guide Error Management Error Management 1 Error Management If an error occurs an error message will be displayed in plain language on the teach pendant see Figure 1 If several errors occur simultaneously the error that occurred first will be selected Error 50028 Motion Jogging error Jogging was made in wrong direction when a joint was out of working range 1 1 Log 50028 Jogging error 0810 09 25 30 Check OK Figure 1 An error message is displayed in plain language as soon as an error occurs All errors and status changes are also registered and time stamped in a log For more detailed information on these logs see Service in Chapter 14 of this manual 1 1 Confirming an error message e Press OK The window displayed before the error occurred will be displayed once more If you want to view an error message later on
238. ecorder record the values of speed and torque_ref for the external axis e Increase the Tune Value for Kv in steps of 5 and observe torque_ref Stop when the axis starts to vibrate Divide the Tune Value by 2 and run the axis again while observing torque_ref There should be at most one or two damped oscillations after the acceleration stage If torque_ref oscillates more than this then decrease its value somewhat Kv is a critical parameter A large value will result in a stiff axis and a fast response If Kv is too small Kp will also be limited resulting in an under utilised axis User s Guide 12 73 System Parameters 12 74 e Increase the Tune Value for Kp slowly until the following speed and torque_ref profiles are achieved speed Slight overshoot acceptable a No overshoot acceptable time torque_ref One or two damped oscillations acceptable y time The position error lag is inversely proportional to Kp Thus a large value for Kp is desirable e Adjust the Tune Value for Ti downwards in steps of 10 until the effect can be seen on the chart recordings of speed as an increased overshoot Increase the tuning factor by 5 to 10 to remove the effect e Calculate the final values of Kp Kv and Ti by multiplying the value entered under Lag control master 0 by the Tune Value divided by 100 Enter these new values for Kp Kv and Ti under Lag control master 0 Tuning of Df The dynamic factor Df
239. ecosseooessscesosessosee 8 Dy Whatisa TOn Aenea a a aaa aa 8 3 2 The Program Routines Window 4 iccius dccsieecssvsisetedcastatiasianssacecessaentcadeleteaeetervacdeses 9 Died METS ALI a neW TOE e ea E E EE E T E ae 10 3 4 D plicating a routine A ceedesesersdsevgieaducvs aces wesc ea a a E E E S 11 4 Creating new instructions seessccessocssscesocesooesoocsssecssocesocesoocesocesoecesocesocesoocesscessocesoose 12 4l Choosing a TOUN sneis io seien o E E ia Ae a ES iA 12 4 2 The Program Instr window essssesesssesessseessressesssessseesseeessresseesseesseeessseesseesseessee 12 4 3 What is an instr ction stseene a ero aa isi 13 4 4 Getting more information about an instruction sssesssssessseesseessessseresseeesseessresse 14 S Pro raMmMiNt sisis sserssocse tasot ossarose ro sebesen cane oa eisiaa iso TE ae 14 5 1 Choosing from the instruction pick list sesseeseeseeessseesseseseressersresrersersrerreesreseee 15 35 2 CAD ay ATSC OD gs iesse a a a E RE ASE 16 Dd EEK KATO EAEE E ea IO eee Sa a ea ad E Ak a 18 5 4 Moving and copying instructions 0 eeceeeeccecsseceeseeeecseeeecseeeseeeeesaeeessaeeeesaeeeenas 21 6 Running Programs sssssssssssssssssssscssssnssss sssesesssossssesosdsasis osssscssssesssstotssbostodsssss sss sssosss siss 21 6 1 Program execution a e ti g a e a e a a a Aae aaa 21 6 2 The Program Test WINGOW f 3 cc5 cececs mekacacttiad aa ctaaageeatalacadenatinal teeaaseenaliatones 22 6 3 Choosing the sp
240. ect 10 38 delete data 8 52 file 13 6 instruction 8 36 module 8 57 routine 8 36 digital output change manually 7 6 directory 13 3 create 13 5 delete 13 6 diskette 13 3 format 13 7 displacement 9 6 displacement frame change 10 43 10 44 Display 4 10 Duplicate data 8 50 8 58 routine 8 58 duplicate routine 8 11 E elongator point 10 29 ELSE 9 13 20 2 Emergency stop 4 9 emergency stop 5 6 Enabling device 4 10 enabling device 5 5 Erase All Logs 14 6 Erase Log 14 6 Error Handler 8 52 error log 14 4 error management 18 21 error recovery 8 52 Event Routines 12 38 12 39 12 40 12 41 12 42 execution mode 8 23 expression 8 18 external axes defining 12 63 jogging 6 16 external manipulator 12 62 external unit choose 6 16 F Field 4 23 file 13 3 copy 13 6 delete 13 6 move 13 7 rename 13 5 File Extensions 12 45 file manager 13 3 file system 13 3 flp1 13 4 FOR change structure 8 35 format diskette 13 7 function 8 9 FWD 8 23 G Go to selected position 8 27 group of I O change manually 7 6 Groups parameters 12 14 H Hide IPL 8 15 User s Guide I I O parameters 12 9 T O list define Most Common 7 4 IF 9 11 change structure 8 35 In All Modules 8 58 In Module 8 58 Incr 9 14 incremental jogging 4 21 incremental movement 6 14 Info Service window 14 6 input signal define 12 12 inputs outputs manual operation 7 3 Inputs Outputs window 7 3 insert instruction 8 16 instruction 8 1
241. ed GS conflict Status conflict between GS1 and CH1 or GS2 and CH2 after a delayed General Stop Check Replace Panel Board User s Guide BaseWare OS 3 1 System and Error Messages 20234 Immediate ES conflict Status conflict between ES1 and CH1 or ES2 and CH2 after an immediate Emergency Stop Check Replace Panel Board 20235 Immediate AS conflict Status conflict between AS1 and CH1 or AS2 and CH2 after an immediate Auto Stop Check Replace Panel Board 20236 Immediate GS conflict Status conflict between GS1 and CH1 or GS2 and CH2 after an immediate General Stop Check Replace Panel Board 20241 Key speed status fault Status conflict for the operating mode key signals and the speed signal Check Check operating mode key hardware or replace Panel Board 20242 Auto mode conflict Status conflict for the operating mode key signals in Auto operation Check Check operating mode key hardware or replace Panel Board 20243 Manual mode conflict Status conflict for the operating mode key signals in Manual operation Check Check operating mode key hardware or replace Panel Board 16 33 System and Error Messages 20244 Manual FS mode conflict Status conflict for the operating mode key signals in Manual Full Speed operation Check Check operating mode key hardware or replace Panel Board 20251 Transformer temp high Status active for over temperatur in main transformer
242. ed and press Enter by pressing Add e Select the desired parameter and change its value e Press OK to confirm To delete a unit e Select the appropriate unit e Press lt pa or add a new one All the signals on this unit will remain defined These must be deleted separately User s Guide 12 9 System Parameters 12 10 Parameter Unit Name Unit Type Unit Bus Address Digital Outputs Digital Inputs Analog Inputs Analog Outputs PollRate Disabled Description The name of the unit max 16 characters Unit type see also 3 2 below Compare with the designation on the cover of the unit Unit type e7p000 is used for simulated digital and analog sig nals This simulated unit can handle up to 100 digital inputs 100 digital outputs 30 analog inputs and 30 analog outputs For more information about the selected unit type press the function key Info The bus on which the unit is located normally BASE All units that are connected to the SIM bus will be simulated The address of the unit on the BASE bus according to the physical keying see Product Manual Installation and Commissioning The number of digital output signals to be used The number of digital input signals to be used The number of analog input signals to be used The number of analog output signals to be used Some units needs to be polled to update input and output sig nals The parameter spe
243. ed in the room and the robot movements in these coordinate systems will be independent of simulta neous gantry or track movements This coordination is automatically active if the mechanical unit with the track motion is active The second coordination category is when the robot movements are coordinated to the movements of a user frame connected to a mechanical unit E g a user frame may be placed on a turntable and connected to its movements An ordinary work object may be used for this purpose if it is marked with the name of the mechanical unit to be con nected to and that it should be moveable The coordination will be active if the mechanical unit is active and the coordinated work object is active When such a coordinated work object is used in jogging or in a move instruction the data in the uframe component will be ignored and the location of the user coordinate system will User s Guide 10 5 Calibration only depend on the movements of the mechanical unit However the oframe compo nent will still work giving an object frame related to the user frame and also the dis placement frame may be used 3 Calibration 3 1 What is calibration Calibration involves setting the calibration positions zero positions of the axes and is used as the basis for their positioning If the robot or external axes are not correctly calibrated this will result in incorrect positioning and will have a negative effect o
244. eed Correction ss csdsissvcsissiaseacsvavavacaasecesasiavcsadestndeaees tecsasteseesaceasnacs 22 6 4 Choosing the execution mode ssseessesssessseseesstessresserssereseessseessressersseessseesssets 23 6 5 Starting program execution s ssseesssessseesserssesseresseetsstesstresstesseresseeesseesseesseesseet 24 6 6 Stopping program Execution 3 2 4 6c eee ate cae 25 6 7 Where will the program start sessseeesseessessseeesseessseessressresseresseeesseesseesseesseeesseee 25 6 9 Sim latins Wait c nditi NSsnesseei eeni E R N A EN 27 7 Saving and Printing ProgramS eesseessecsccescosesoecssecssocesoossoocessecssocesocescocesocessecesecesooeeo 28 7 1 Saving the program on diskette or some other type of mass memory 0 28 7 2 Printing a program from the robot nnuis a nck ASA AGG 29 7 3 Printing a program using a PC s ccsaci tj cesasicadedeayseseceessesdeatacosnaacsacdededsonceadecansdactoess 29 Changing the Prager anne icsciccsnceeuceahci vascpu tees aap sees cesw Gav pcan cock cashaavacayy gees scans oucov oevansngeneens 29 8 1 Selecting an instruction OF an argument 0 eee eeeeeeeetececeteeeeeeeeeneeeesaeeeenaeeeenas 30 User s Guide 8 1 Programming and Testing 8 2 Modifying the position in a positioning instruction lees eeeeeeeeeereeceeeeeeeeeees 31 8 3 Tuning position during program execution 0 0 0 eeeeeceeeeeeeeeeeceeeeeceeeeceeeeenaeeeenes 31 OA Changing AN ALS UMISML ge ieten r
245. eed can be carried out as follows e Set the operating mode selector to 100 e Programs can only be started using the teach pendant with the enabling device acti vated For Hold to run control the Hold to run button must be activated Releasing the but ton stops program execution The 100 mode may only be used by trained personnel The applicable laws and regulations of the countries where the robot is used must always be observed Automatic operation Automatic operation may start when the following conditions are fulfilled e The operating mode selector is set to The MOTORS ON mode is selected Either the teach pendant can be used to start the program or a connected remote control device These functions should be wired and interlocked in accordance with the appli cable safety instructions and the operator must always be outside the safeguarded space 7 4 Enabling device When the operating mode selector is in the MANUAL or MANUAL FULL SPEED position the robot can be set to the MOTORS ON mode by depressing the enabling device on the teach pendant Should the robot revert to the MOTORS OFF mode for any reason while the enabling device is depressed the latter must be released before the robot can be returned to the MOTORS ON mode again This is a safety function designed to prevent the enabling device from being rendered inactive When the enabling device is released the drive power to the motors is switched off
246. eed several times or reset welding equipment with power switch If the error do not disappear check bus connections and or exchange Wirefeed Unit 117315 Welding equipment error Wirefeed Unit has detected that a received internal CAN message was lost overwritten by a later message Check Reset welding equipment with power switch 117326 Welding equipment error Program execution error Watch dog in Wirefeed Unit program activated Check Reset welding equipment with power switch 117327 Welding equipment error Undocumented Wirefeed Unit error Check Request additional information from ESAB ABB User s Guide BaseWare OS 3 1 System and Error Messages 117328 Welding equipment error Undocumented Wirefeed Unit error Check Request additional information from ESAB ABB 117329 Welding equipment error Undocumented Wirefeed Unit error Check Request additional information from ESAB ABB 117500 File error Failed open file File name unknown Check Check file name 117501 File error Failed writing to file Check Check file name 117502 File error Failed reading from file Check Check file name 117503 Illegal schedule number Schedule number 16s is not allowed Check Change schedule number 117504 Communication error Message header form Arcitec power source unknown Check Check connection to power source Check Arcitec configuration file 117505 Communication err
247. eees 44 8 14 Using the robot to change a displacement frame 0 ee eee eeeeeeeeeesteceeeeeeeeeeneees 44 10 2 User s Guide Calibration Calibration 1 Coordinate systems All robot positions in a robot program are stored in rectangular coordinates e g xyz values for position related to a defined coordinate system or frame This coordinate system may in turn be related to another coordinate system etc in a chain Some of these coordinate systems are embedded in the configuration of the robot system and are not visible to the user while others may be programmed by the user The table below provides an overview of the various coordinate systems or frames used in the robot system Coordinate system Defined where Related to Base Frame of robot Service View BaseFrame World Frame Base frame definition of robot gives relation between world and base frame World Frame No definition needed Nothing User Frame fixed in room Program View Data Types wobjdata World Frame Tool mounted on robot In any work object data User Frame fixed on robot mounting plate Tool fixed in room Program View Data Types wobjdata In any work object data Wrist Frame User Frame coordinated to an external Service View BaseFrame World Frame axis In the base frame definition of an external mechanical unit Object Frame Program View Data Types wobjdata User Frame In any work object data Program
248. eem asio Sasi E Osii ESSAS 50 11 1 Viewing and possibly changing the current value oo cee eeeeeeseecneceeeeeeeeeenees 50 11 2 Changing data names or declarations 0 eeecceesceceececeenceceeeeeceeceecsceecsteeeenaeees 51 Tel SSMU AL Asses ve avo nce dg E E E E E ous natdegany ado E E TEE 52 I2 Error Fi Qian 5 eosas cys osecucvesacaveveadecuce cases cycsivas ons asseatvean ea devisdecacedenvan sadas o ksosa iias 52 13 Usma Mod l s 53 cack vesces casts seansieasibiu cbs ccuecaaabs suelead basa sidsiivaxiuanisbeebaciashu ees biavatduteadecaniessucioest 54 T31 What isa mod l iarere ingere ti e Maral etii 54 13 2 Choosing m d leS neen sae e are E E S R EE E E EE NEE EES 55 13 3 Creating a new MOCUIE ics cissaceietsnses ievavases Gisbevaterseseacsaseavaasasopandeansaeetue TEE aaRS 56 13 4 Changing the name or declaration of a MOdUI e ee eee eeeeceeeeeeeeeneeeneeeeees 56 13 5 Reading a program module from diskette or some other type of mass memory 57 13 6 Deleting program modules from the program ee eeseeseeeeeeneeesseenseeeeeeeenees 57 13 7 Listing all routines in all modules nnssnnsseeeeneeesseessesssessseeesseeesseessessseessseeessees 57 13 8 Duplicating a routine from one module to another 0 0 0 ele eee eeeeeeneeeneceteeeeees 58 13 9 Listing all data in the current MOdUIe eee ee ene ceeeeceeeeeceeeeeceeeeeceeeeeeneeeees 58 13 10 Duplicating data from one module to another eee eeeeeeseecseceeeeeeeeeenees 5
249. eesseesseessersseeesees 8 36 8 9 Deletins a TOUUINE actin cack e N E R E 8 36 8 10 Undo Tate SU ACTION settist iii e isiat ie ists 8 36 9 Special Editing Functions sessoessocssscssocesocessocsssesssocesocesooesoosesocsssecesocesocesoosesse 8 37 9 1 Searchy amp replace va ccnssessascaedesveszareseanscaeasaceeanaavensceeieseaeentuavearerevanesusnaiacvetedenere 8 37 92 IVE IE NS ic ian Silo alae Dec a aI aN Gilad lala Da asthe Desk 8 39 10 Creating DD ACE sass cca svnnsedesonceeoraceuieanctssunvsnaceusenecsonseduouesouss axpatuonsussnsueeuuvereivestensees 8 45 10 1 Wihat ts data tossed 8 he Gis cece ieee eae Ea EAE ea as 8 45 10 2 The Program Data window used to manage data ceeeeeeeeeeseeeeeteees 8 45 10 3 Creating new Cal el ote cas tetera cor atans ote tented Gajesaere aad cosa a heeding 8 47 10 4 Creating new array data sis ucensdsysiascidetetessavhgessea tedackssomeeeanereeumeeu 8 48 10 5 D plhicatng datate ien a E E a ai 8 50 10 6 Storing position data using the robot sesssesssessessseesseresseeesseesseesseesseee 8 50 10 7 Routine datasssenssi unssin sian ianiai e A iE 8 50 11 Chabtins Dataisosiiccesitsrotsniissose tis veveotsssocuiess sesoses resents ees isotoopi seias 8 50 11 1 Viewing and possibly changing the current value eee eeeeeeeeeeneeeeeeeees 8 50 11 2 Changing data names or declarations ssssesssesessseesseesseesseeessseessresseesse 8 51 User s Guide 11 3 Deleting data siyicatisseace
250. eld error MESSAGES cssscccsssccsssscsssscsssssccssccssscccssscssssscscssscssesssssesssssesseees 16 92 10 Paint error MESSAGES sss iseccecssssensesssschcacssvseadsssdtrecessecvesdansssddsessdeassisivadentessdenen s 16 93 17 Program Examples sce cisvscccdesacssccntseivncsseacebasdessecedesclsnvsscuddecsessteneteesseves L J l 1 Simple Material Handling eeesooescoessccssocesocesoossssesssocesocesoosssocessesssosesoosssosessee 17 1 1 1 What the ert bot COC Sunsin i dated turadlos Gates taeadaord n a aidai 17 3 1 2 Thema TONS oe s ursii tt a a i eed ae es 17 3 1 3 Operating the Brip pen ipis ont norin aT EESE a aa TEET 17 3 1 4 Fetching a part from the In feeder oseeeeeeeeeeeeseeeesseseresressessresressessrerreeseese 17 4 1 5 Leaving the part in the machine ssssesesssesessseesseesseesseesseresseeesseessesseeesees 17 4 1 10 User s Guide 1 6 Starting 10 Process sosisini srini eii niies iiai esaa heapestarensuctasens 17 5 1 7 Fetching the part from the machine 2 i004 uc4otavvina edad 17 5 1 8 Leaving the part on the Out feeder nsnnsnnssensseeeseeessseesseesseesseessseessseesseese 17 5 2 Material Handing vi ss isvseseslescsvaeivaciescssvacisscsacavesssscebanceasasausbaasaceuunaivasdesssiacicasdvsdsas 17 7 2 1 What the fobot OS sx sciasssassadesarsesaataays ca tandaies euandeaate nenen ens 17 7 25 es Fhe AMAL OW IIIS nene sacks tuey oan Gry Siac a R A ended waa 17 7 2 9 Op tatine ASOT PPErjae5 Foes See v
251. elect the field In Module and press Enter State the name of the module where the data is to be sent e Press OK to confirm Note Do not change the work object type This must always be of the persistent type 8 4 Manually updating the user and object coordinate system of the work object e Open the Program Data Types window by choosing View Data Types e Select the type wobjdata and press Enter J e Select the work object to be changed and press Enter e Select the component x y z q1 q4 that you wish to change e Change the value using the numeric keyboard To enter a decimal point and minus sign use the function keys e Choose OK to confirm Note Ifthe work object is defined using a movable user coordinate system only the object coordinate system need be defined The user coordinate system is defined in the Service window See Coordinated external axes on page 16 8 5 Methods of defining a work object The methods used to define the user and object coordinate system are called No change No changes to the definition of the user or object coordinate system will be made i e the definition of the user or object frame will be left as it is 3 point Three points are used two points on the x axis and one point on the y axis see Figure 33 A tool with a known TCP is required Object Z User User XI Y1 Y XI Figure 33 Measuring points for defining
252. en consecutive close positions 50079 Wrist weaving not possible Check Use smaller weaving amplitude or a larger TCP 50080 Position not compatible Position cannot be reached with the given robot configuration Check Modify the robot position in the program 50082 Deceleration limit Calculation of joint deceleration time exceeds internal limits for this motion Check You cannot proceed without removing the cause s of this error see Check Increase path resolution sys param or by PathResol for critical movements Reduce speed use fine increase AccSet increase Queue time avoid singularity SingAreaWrist inc dynamic resol User s Guide BaseWare OS 3 1 System and Error Messages 50083 Speed lowered by system The speed has been lowered by the system due to dynamic limitations Check Decrease speed and or do not use close positions at high speed and or increase acceleration if below 100 50085 Too many user frames For mech_unit s more than one user frame has been defined Check Take away one user frame or define one more mech_unit 50086 Singularity calc error Too close to wrist singularity with respect to numerical resolution for joint 4 of IRB Check Change destination position a few increments 50087 Singularity problems Too close to wrist singularity with respect to numerical resolution for joint 6 of IRB Check Change destination position a few increments
253. en the reply is a numeric value e Press OK e If text is displayed above the function keys you can give your answer by pressing the desired alternative see Figure 11 Select program to run FrontA FrontB FrontC Other SERVICE Figure 11 Operator dialogs can be tailor made to suit any robot installation The dialog window shown in Fig 10 can only be exited in one of two ways either by answering the question or by stopping program execution 11 10 User s Guide System Parameters CONTENTS Page System PAaramiGlers cccsioedsiecceticensaceceecccessulccncuseasecanacesssesedtececbansdonscuuthaseosteacs 3 1 CHaneini ga Parameter jiciesdccececsvveccsvndsdeduesshededsesseatovstdscacecepwacevendedvevesivescotadacatpenioacenodeied 3 1 1 SubdivisiGnvoOl Paranneters lt 352e 3 Jet ae eek aehoed ation ln e E ARN 3 1 2 Changing a AL AMIE LEDs xcs nresep ga E E E OE EEEE o ENEE SEE OE uS 3 1 3 Deleting parane teknenin E E E E N meena eeaceee aaa 4 LA Generating a restart siiente intei a ea paa T EENES S 4 1 5 Viewing the last changes that were made eessesseeeeseseseeeeesersrrseresressrseresressesee 5 1 6 CHECKING Parameters o innri neee a dees a A EEN 5 2 Saving and Loading Parameters ssesssessocesooessocsssesssocesocesoosesocessecesocesooesoosesseessocesoose 6 2 1 Saving parameters to diskette or some other mass storage deVICE eee 6 2 2 Loading parameters from a diskette or some other mass storage device
254. eprog ManInterrupt Add Figure 11 Input signals can be assigned specific system actions e Select the system input to be changed and press Enter or add a new one by pressing Add e Define the name of the signal and the system action that is assigned to it To add the system actions MotOnStart Start StartMain Interrupt LoadStart and Sync ExtAx define their arguments as well Press OK to confirm The following system actions are available System action Description MotorOn Sets the robot to the MOTORS ON state 12 22 User s Guide MotOnStart Motoroff Start StartMain Stop QuickStop StiffStop StopInstr StopCycle SysReset Interrupt ResetError SyncExtAx LoadStart User s Guide System Parameters Sets the robot to the MOTORS ON state and starts the program continuous or cycle execution from the current instruction i e from the program pointer Sets the robot to the MOTORS OFF state If a program is executing it will be stopped before changing state The robot cannot be set to the MOTORS ON state when this signal is high Starts the program continuous or cycle execution from the current instruction i e from the program pointer Starts the program continuous or cycle execution from the beginning Not valid during program execution Stops program execution A program cannot be started when this signal is high Stops program execution
255. er Replace external drive unit Replace Robot Computer Board 39310 External Drive Stop External drive joint s has order a program stop Check See documentation for Atlas DMC FBU 39311 External Drive EM Stop External drive joint s has order an emergancy stop Check See documentation for Atlas DMC FBU 39320 External drive error Time out in communication with exter nal drive unit joint s Check Restart system and external drive Replace external drive See documentation for Atlas DMC FBU 4 Program error messages 40001 Argument error Task 16s More than one occurence of optional parameter 16s Check Make sure that the optional parameter is not specified more than once in the same routine call User s Guide BaseWare OS 3 1 System and Error Messages 40002 Argument error Task 16s Excluding arguments must have conditional value 16s has value Check Arguments may not be specified for more than one parameter from a list of parameters that exclude each other unless all values are conditional argument values 40003 Argument error Task 16s Expecting argument for required parameter 16s but found optional argument 16s Check Check that the arguments are specified in the same order as the parameters for the routine being called 40004 Argument error Task 16s Argument for REF parameter 16s is not data reference Check Make sure the
256. er A weld data block transmission has been faulty received Reset welding equipment with power switch 117025 Welding equipment error Incompatible format of weld data block Welddata Unit received data that is stored in another program version with other format version Check Find data with correct version or enter new data 117026 Welding equipment error Program execution error Watch dog in Welddata Unit program activated Check Reset welding equipment with power switch User s Guide BaseWare OS 3 1 117027 Welding equipment error Undocumented Welddata Unit error Check Request additional information from ESAB ABB 117028 Welding equipment error Undocumented Welddata Unit error Check Request additional information from ESAB ABB 117029 Welding equipment error Undocumented Welddata Unit error Check Request additional information from ESAB ABB 117201 Welding equipment error EPROM checksum error in Powersource Control Unit Check EPROM in Powersource Control Unit is faulty Running with this error gives unpredictable result Replace EPROM 117202 Welding equipment error Internal RAM read write error in Powersource Control Unit detected at power up Check At least one memory cell in internal microprocessor memory failed in read write test Running with this error gives unpredictable result Replace Powersource Control Unit 117204 Welding equipment error DC supply voltag
257. er than min 71009 Type invalid DescriptionReason Signal s the type of signal is invalid Check 1 Change the type User s Guide Base Ware OS 3 1 71010 Signal out of range DescriptionReason Signal s the physical signal number length 1 cannot exceed max physical signal number for the unit Maximum value d Check 1 Change the physical signal number 2 Change the length 3 Check the signal type 71015 Digital Input overflow DescriptionReason Number of digital input channels for board s is greater than d Check 1 Reduce the number digital inputs 71016 Digital Output overflow DescriptionReason Number of digital output channels for board s is greater than d Check 1 Reduce the number of digital outputs 71017 No activate signal DescriptionReason Missing activate signal for cross Check 1 One activate signal must be given 71018 Activate signal overflow DescriptionReason Number of activate signals for cross too high Check 1 Only one activate signal must be given 71019 Missing signal definition DescriptionReason The signal s at cross is not defined Check 1 Define the signal name in signal section User s Guide BaseWare OS 3 1 System and Error Messages 71020 No result signal DescriptionReason Missing result signal Check 1 At least one result signal must be given 71021 Duplicate cross signals DescriptionReason The signal
258. er the parameter Use act relay the name of the activating relay e When more than one activating relay is used read in a new relay file file RELAY and repeat the procedure above Define brake relays if any are connected If the external mechanical units are equipped with brakes these will be automatically activated when the unit is deactivated or when the robot system assumes the MOTORS OFF state They will also be activated when the axes have been stationary for a certain time in the MOTORS ON state e Defining the input and output signals for the relays See Defining input and output signals on page 12 Start the robot with File Restart and check that the brakes can be activated from the I O window e Read ina relay configuration file EXTAXIS UTIL RELAY from the Control Parameters diskette See Loading parameters from a diskette or some other mass storage device on page 7 Use the command File Add new parameters A new relay with the name RELAY _x is now be created e Choose Area Manipulator e Choose Types Relays and specify the name of the relay and its signal connections See Define activating relays if any are connected on page 68 e Choose Types Mechanical unit and specify under the parameter Use brake relay the name of the activating relay The time after which the regulator will cease to brake and let the mechanical brakes themselves brake can be changed by choosing Types Brakes Parameter Description C
259. ergency stop Check Close runchain it could be broken by the following devices if used Access gate light screen servo disconnector or any other safety device connected to the run chain 10013 Emergency stop state Runchain opened by emergency stop Em stop reset is required Use the motors off button User s Guide BaseWare OS 3 1 System and Error Messages 10014 System failure state Fatal non recoverable system error Warm start is required 10015 Manual mode selected 10016 Automatic mode requested 10017 Automatic mode confirmed 10018 Manual mode FS requested Manual mode with full speed requested Check 10019 Manual mode FS confirmed Manual mode with full speed confirmed 10020 Execution error state The program execution has reached a spontaneous error state 10021 Execution error reset The program execution has left a spontaneous error state 10022 Hold to run waiting Waiting for hold to run button to be pressed on the programming unit 10023 Hold to run timeout The hold to run button on the programming unit must be pressed within timeout limit 10024 Collision triggered A collision has been detected 10025 Collision resetted The collision detection has been resetted 10026 Collision confirmed Returned to the path after a collision detection 10027 Collision not confirmed The system has not returned to the path after a collision detection 16 25 System and Error Messa
260. ernal Trans Max External Rot If Auto 6 5 Programmable keys Description The current type of modpos ModPos means that Limit Mod Pos is deactivated i e any change is accepted LModPos means that Limit ModPos is activated i e the change must be within a limited area Tuning Off or On in auto On tuning functionality enabled in automatic mode Off tuning functionality disabled in automatic mode The current mode of limited modpos Abs The limited area is around a fixed original point Rel The limited area is around the current point and will be moved when you modify the point The maximum allowed deviation in mm from the current or original position The maximum allowed reorientation in degrees from the cur rent or original position The maximum allowed deviation in mm from the current or original position concerning external linear axes The maximum allowed deviation in degrees from the current or original position concerning external rotational axes Parameter for automatic activation of Limit ModPos when the operator s key is switched to Auto Mode LModPos means that Limit ModPos is activated when the operator s key is switched to Auto Mode As Is means that ModPos is not changed There are five keys on the teach pendant which you can define for the purpose of setting outputs and generating signal events see Figure 26 AA ED ED FADED Figure 26 The five programmable keys e Choose Topics Tea
261. ero speed with maximum torque Speed sup trim factor Tune factor for speed supervision The factor influences the maximum allowed speed error Pos sup trim factor Tune factor for position supervision The factor influences the maximum allowed position error 7 4 Tuning the motion supervision Motion supervision is the name of a collection of functions for high sensitivity model based supervision of the robot s movements The motion supervision includes func tionality for the detection of collisions jams and incorrect load definitions The motion supervision can be tuned through the system parameters Separate parameters exist for jogging and program execution Currently the names of the system parameters refer to the collision detection However they also turn on and off and modify the supervision levels of the load and jam supervisions If the motion supervision is triggered then do one of the following e If the load is incorrectly defined use the load identification function to define it e If the application involves many external process forces increase the supervision level for jogging and program execution in steps of 30 percent until you no longer receive the error code e If the external process forces are only temporary such as closing a large spotweld gun then use the instruction MotionSup to raise the supervision level or turn the function off temporarily e If everything else fails turn off the motion superv
262. error can then be remedied in the error handler and the program can be automatically restarted as in the example in Figure 45 Main routine read_diskette read_diskette MoveJ T Set dil ERROR ERROR IF ERRNO ERR_FILEOPEN THEN Remedy the error by for example requesting the operator to insert the I correct diskette RAISE RETURN RETRY TRYNEXT mal Figure 45 The program can be restarted from the error handler in various ways 8 52 User s Guide Programming and Testing If the program cannot read a diskette a jump is made to the error handler of the routine where the error is remedied The program can then be restarted by re executing RETRY the instruction that caused the error executing the next instruction TRY NEXT or by returning RETURN to the calling routine The error can also be remedied in the error handler of the main routine RAISE To create an error handler e Choose View Routines e Choose the routine to which the error handler is to belong e Choose Routine Add Error Handler To program the error handler e Choose the routine to which the error handler is to belong In the Routine window Choose Routine Error Handler In other windows Choose View Error Handler e Program the error handler in the usual way e Return to the main part of the routine by choosing View Instr To remove an error handler e Choose View Routin
263. es e Choose the routine to which the error handler is to belong e Choose Routine Remove Error Handler User s Guide 8 53 Programming and Testing 13 Using Modules 13 1 What is a module The robot program can be subdivided into program modules each module containing a group of routines and data In addition to this system modules which are always present in the memory can be used see Figure 46 Program memory Program Main module routine Modules Program data System modules j Figure 46 Routines and data can be grouped together to form modules The entire program or separate modules can be stored on diskette or some other type of mass memory System modules are automatically loaded when the system is cold started 8 54 User s Guide Programming and Testing A module can include for example general routines for many different installations positions generated via CAD routines for a certain type of external equipment such as a workpiece manipulator System modules can for example include general data e g tool data for all programs used in the same robot The main routine of the program is located in one of the modules the module with the same name as the program Both program and system modules work in the same way once they have been loaded into the memory All modules can normally be edited using the teach pendant but as system modules are often write pro
264. esaciee 16 1 1 Error Management sissscssicescctcectaatidicvscesssacastenssdenstesscnaccesansesteiissscnsecdstseesecaacessasian 16 3 1 1 Confirming an error Message eseseseeeseeeeesersrerrerstsreseresresetsrresresseseresresee 16 3 1 2 Calling up suggestions on how to correct an errot essssseseseereesererrereesee 16 3 1 3 Acknowledging warning messages seesseseseessseeesseesserssereserersseessresseessee 16 4 16 System and Error Messages sscccecssosoesesssscoccessssoceceessosoesesssssoesssssseo 16 5 1 Operational error messages sesssecssecsccesooessscessocesocssooseoocesoeessocesocesoosssossssessseee 16 7 System error Messages e sseesseessooscosccossssocsscoscosseosesoseessoessocesssessseessesssossesseesssssse 16 9 Hardware error messages eessscsecesssecessocesssooesesooecesooccesosoosessoossssooeeesoseeessseessse 16 16 Program error messages seesssscoesesoscesosooesssoceessooecesosecesosoosessoosessosesesssesessssesss 16 31 Motion error messages sssesssesssecssocesosesocessccssocesocesooeesocsssecesocssoosssoesssesssesssosese 16 58 Operator error MeSSagesS e seessccescocssocssocesocesooesoocessccssocssocesooesssessseessocesocsssosssse 10 68 IO amp Communication error messages sccsssscssrccssssccsssccsssscssesscessscsssssees 16 72 Arcweld error MESSAGES e ssssecesssosecesoccesssoossssooceesooecesosocesosoossssoossessoesesssesssssss 16 83 PANDA NN BR WwW WY Spotw
265. esocesocesooesssesssecesoeee 14 User s Guide 9 1 The programming language RAPID 9 2 User s Guide The programming language RAPID The programming language RAPID 1 Programming a Position 1 1 Positioning instructions L J c A positioning instruction contains the following information Type of path e g linear joint motion The destination position to which the robot is to move Speed Zone size accuracy i e how close the robot must be to the destination position before it can start to move towards the next position If fine is chosen the robot moves to the position Current tool TCP of path Speed specified in the speed data v100 100mm s linear Joint Zone size specified in the zone data z10 10mm circular Tool TCP xN Y MoveL p1 v100 z10 tooll A Destination position stored in instruction pl stored in position data pl The speed and zone size refer to different data which includes the desired speed in mm s zone size in mm etc You can create and name this data yourself but the most commonly used values are already available You specify the tool its dimensions and weight in the tool data see Chapter 10 Calibration The TCP of the tool is moved to the specified destination position when the instruction is executed see Figure 1 User s Guide 9 3 The programming language RAPID s 1 3 xe p r P Moe yr ae Soe kS QSQ7 Py S S
266. essness may cause personal injury 5 4 User s Guide Starting up e Turn the key to O Automatic mode is used when running complete programs in production operation In this mode the enabling device on the teach pendant is disconnected and the functions used to edit programs are locked 3 2 Manual mode with reduced speed programming mode e Turn the operating mode selector to amp If the hold to run function is active the function is available by means of a system parameter program execution will stop as soon as you release the Hold to run key on the teach pendant Manual mode with reduced speed is used when programming and when working in the robot working space In this mode external units cannot be remotely controlled 3 3 Manual mode with full speed testing mode only be used by trained personnel Carelessness may cause personal injury 100 In Manual 100 mode the robot moves at full speed This operating mode may e Turn the operating mode selector to 4 The hold to run function is now active i e program execution will stop as soon as you release the Start key on the teach pendant Manual mode with full speed is only used when testing the robot program at full speed In this mode external units cannot be remotely controlled 4 Switching the Power Supply to the Motors On Enabling In automatic mode press the Motors On button on the operator s panel device J In manual mode turn to MOTORS ON mo
267. eter 16s must have transfer mode IN specified value Hi Check Remove the parameter transfer mode specifier If IN transfer mode is not sufficient change the data type of the parameter 40260 Symbol definition error Task 16s switch only allowed for optional parameter not for 16s Check Change the parameter into an optional parameter or change the data type of the parameter If the object is not a parameter change the data type 40261 Type definition error Task 16s Value type class for 16s must be one of REAL_SYMVALTYP_VAL _SEMIVAL _NONVAL or _NONE specified value i Check Change the value type class User s Guide BaseWare OS 3 1 System and Error Messages 40262 Data declaration error Task 16s Too many array dimensions for 16s specified value 1 Check An array may have at most 3 dimensions 40263 Name error Task 16s Symbol name AOs is not a RAPID identifier excluding reserved words Check The names of installed objects including parameters and components must be legal RAPID identifiers not equal to any of the reserved words of the RAPID language Change the name 40264 Symbol definition error Task 16s Missing C function for 16s Check A C function that executes the ReaL function being defined must be specified 40265 Symbol definition error Task 16s Missing value initialization function for 16s Check A value initializat
268. execution Restart is not possible Check Check the number of move instructions with concurrency Move the start point and start a new movement 50024 Corner path failure A corner path was executed as stop point due to some of the following reasons 1 Time delay 2 Closely programmed points 3 System requires high CPU load Check 1 Reduce the number of instructions between consecutive move instructions 2 Reduce speed use wider spaced points use CONC option 3 Increase ipol_prefetch_time User s Guide BaseWare OS 3 1 50025 Restart too far from path Check Move back to path 50026 Singularity or Zone error 1 Robot too close to singularity 2 MoveL to MoveJ corner zone error Check 1 Use the joystick to move away from the singularity or run a program in joint coordinates 2 Use fine point or modify position 50027 Joint Out of Range Joint s is out of working range Check Use the joystick to move the joint into its working range 50028 Jog in wrong direction Joint s is out of working range Check Use the joystick to move the joint in opposite direction 50029 Robot outside its limits The robot has reached the configuration limit for the parallelogram transmission Check Use the joystick to move the involved joint into the working range again 50030 Robot outside its limits Jogging was made in wrong direction when parallelogram was out of working range Check Use the joystick to move
269. eysesSoces secs hed Shas Mase seaeaked a a shod ete S 17 8 2A Slatin production esarri a E a E i 17 9 2 5 Fetching the part from the In feeders aici snilavonundinsclauieedien 17 9 2 6 Leaving the part in the machine seeeeeseeesesseeseessesresseseresressersresreesreseeserssee 17 9 2 7 Updating operating statistics seseeeeseeesseessessseeeserersstesseessrrsseeeseeessseessres 17 10 2 8 Stopping production for the day seeeeseessesseesessresressessresressersresreeseeseeserssee 17 10 18 Quick ReferenCe sssssseseseesceccceccecececocososesesesecececcecececocoeoeosssesssscececceee 18 1 1 Th Josing WiNdOWssisssossersssssscossssossossosesesassosossos sses su sie os sesoses tensso besa iesi 18 3 Tol Window Jogme aeri i eaea cenit ei Oe race E EEEE ee 18 3 2 The Inputs Outputs Window eessoessocsssecssecesocesoosesoecsocessecesocescossooessseessocesoceeo 18 4 21 Window Inputs Outpus n neea a ee e ia 18 4 3 The Pro ram WindOWas se sisierescssscoseseosssrsosradoosssssidosessotobosassdatosesdo pscs idosas soseri os s 18 6 3 1 Moving between different parts of the program eeeesseseereserseresrrsrererssee 18 6 3 2 Cpe Meal TE DUS oc cai2c seuss cawcacesatet asus aca a EEE aE E R EEG taei 18 7 3 3 Window Pro eranieliSi 5 css oscesoessezaigeesoncalccareedesiueedanaseegnes da sence soevSecnniveadons 18 10 3 4 Window Program Routines ceescecesececssececsecceceeececseeeecseeeeeseeeeneeeeaees 18 11
270. f a group of output signals signal by signal by pressing Enter and changing the signals one by one 3 Displaying Information 3 1 To display information on a given signal e Select the desired signal and press Enter The following information will be displayed the signal name the signal type the value of the signal the physical connection cross connections if any etc e Press OK when ready 3 2 To display a chart of all digital signals of a unit e Call up the unit list by choosing View Units e Select the desired unit and press the State function key The values of all digital signals related to the selected I O unit will appear on the display see Figure 6 The values of the signals are indicated by 1 or 0 where for example is equivalent to 24 V and 0 is equivalent to 0 V An x means that the signal is not mapped cannot be used in a program A means that the signal value cannot be read Sigstate I O unit ARCW1 DI 01 1 0 1 1 1 1 0 0 DI 09 0 0 0 1 1 1 0 1 DO 01 1 0 0 0 1 1 0 0 DO 09 0 0 0 0 0 0 x OK Figure 6 The value of all the digital values of an I O unit are displayed together on a signal chart e Leave the signal chart by pressing OK User s Guide 7 7 Inputs and Outputs 3 3 To print an I O list e Select the desired I O list from the View menu e Choose File Print A dialog box will be displayed see Figure
271. f the desired data is hidden by some other object with the same name User s Guide Base Ware OS 3 1 40075 Reference error Task 16s 16s not function reference Check The specified name identifies an object other than a function Check if the desired function is hidden by some other object with the same name 40076 Reference error Task 16s 16s not label reference Check The specified name identifies an object other than a label Check if the desired label is hidden by some other object with the same name 40077 Reference error Task 16s 16s not optional parameter reference in conditional argument value Check The specified name identifies an object other than an optional parameter Change the name to refer to an optional parameter 40078 Reference error Task 16s 16s not optional parameter reference Check The specified name identifies an object other than an optional parameter Change the name to refer to an optional parameter 40079 Reference error Task 16s 16s not procedure reference Check The specified name identifies an object other than a procedure Check if the desired procedure is hidden by some other object with the same name User s Guide BaseWare OS 3 1 System and Error Messages 40080 Reference error Task 16s 16s not required parameter reference Check The specified name identifies an object other than a required parameter Change the n
272. fining the positive x direction e Modify the position by pressing the function key ModPos User s Guide Calibration e Select the measuring point User Y1 e Jog the robot as close as possible to a point on the positive y axis e Modify the position by pressing the function key ModPos To record measuring Points for the object coordinate system e Select the first measuring point Object X1 e Jog the robot as close as possible to a point on the x axis e Modify the position by pressing the function key ModPos e Select the measuring point Object X2 e Jog the robot as close as possible to a point on the x axis defining the positive x direction e Modify the position by pressing the function key ModPos e Select the measuring point Object Y1 e Jog the robot as close as possible to a point on the positive y axis e Modify the position by pressing the function key ModPos To calculate the user and object coordinate system e Press OK to calculate the coordinate systems When the calculation is finished a dialog like the one shown in Figure 35 will appear Work Object Calculation Result Wobj wobj4 User 50 57 0 00 231 82 Obj 150 56 30 02 1231 81 Calculation Log Status 1 10 User Method 3 points Quaternion 1 1 000000 Quaternion 2 0 000000 Quaternion 3 0 000000 File Cancel OK Figure 35 The result of a work object calculation Field Description User The origin of the user c
273. firm A maximum of 60 signals can be cross connected Make sure that the same signal is not connected on both the From and To sides in the same chain To delete a cross connection e Select the appropriate cross connection e Press CX Cross connections with logical conditions Option The digital I O signals can have the logical conditions AND or OR to set up a condition for a cross connection These conditions cannot be entered from the teach pendant They are instead set up in the configuration file EIO CFG in the cross connection sec tion starting with the line EIO_CROSS using a standard PC The same rules apply to the logical condition connections for the result signals as for the normal cross con nected result signals The actors in the cross connection section have the logical con dition operators The logical condition operators are AND syntax in configuration file amp 667 OR syntax in configuration file For each logical condition connection there can only be one kind of logical operator Each logical condition connection can be seen as a logical operator box The AND operator has the following function User s Guide System Parameters If all in signals actor signals to the AND box are high the result signals will be high The OR operator has the following function If any in signals actor signals to the OR box are high the result signals w
274. fo 2 Position The tuning function in the Production window makes it possible to tune the x y and z coordinates of a robot position see Figure 7 The tuning can be performed either when status is Stopped or when status is Running File Edit View Production Position PROG1 Routine main Status Stopped Speed 75 Running mode Continuous Robtarget q Tuning Present 1 1 No Data Figure 7 The Production Info view No robtarget selected e Select the field Robtarget and press Enter Robtarget selection field e Choose the position to be tuned in the list that will appear e Press OK or Enter to confirm the choice File Edit View Production Position PROG1 Routine main Status Stopped Speed 75 Running mode Continuous Robtarget p110 Tuning Present 1 3 x 0 00 xx xxX mm y 0 00 yy yy mm z 0 00 ZzzZz zz mm a Coordinate list Tune Figure 8 The Production Position view with a robtarget selected e Choose the x y or z coordinate in the coordinate list see Figure 8 e Press Tune 11 8 User s Guide Production Running A dialog will appear where you can tune the position e Enter the desired tuning value and press Enter No change 0 Max change in one step 10 mm Several steps can be entered The p
275. g Enter Create a new directory by pressing the New Dir function key Specify the new direc tory name in the dialog box that appears Choose OK to confirm e Choose OK to confirm the save 4 Calibration 4 1 What is calibration Calibration involves setting the calibration positions of the axes and is used as the basis for their positioning If the robot or external axes are not correctly calibrated this will result in incorrect positioning and will have a negative effect on the agility of the robot The robot is calibrated on delivery For more information see Calibrating the robot in Chapter 10 Calibration in this manual 14 8 User s Guide Service 5 Commutation 5 1 What is commutation Each motor must be commutated in order to be able to utilise it to its full capacity Commutation involves reading the resolver value when the motor is in a given pose The robot motors are commutated on delivery For information on how to do this see the section on Repairs in the Product Manual 6 Frame Definition See Frames in Chapter 10 Calibration in this manual 7 Two Axes Definition See Frames in Chapter 10 Calibration in this manual 8 Obtaining information on the robot system e Choose View System Info A list of topics is shown in the dialog box see Figure 5 EEE Service System Info Select topic and press Enter Topics 1 6 Storage capacity Task state System ID Product
276. ge execution mode when the Hold to run button is released and then continue the program execution with the new execution mode by just activating the Hold to run button again i e no alert box is shown If the program execution was stopped with the Stop button on the teach pendant the program execution will be continued by releasing and activating the Hold to run button When the enabling device on the teach pendant is released the sequence described above must be repeated from the beginning 7 6 General Mode Safeguarded Stop GS connection The GS connection is provided for interlocking external safety devices such as light curtains light beams or sensitive mats The GS is active regardless of the position of the operating mode selector When this connection is open the robot changes to the MOTORS OFF mode To reset to MOTORS ON mode the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations This is not normally done by resetting the device itself User s Guide 3 9 Safety 7 7 Automatic Mode Safeguarded Stop AS connection The AS connection is provided for interlocking external safety devices such as light curtains light beams or sensitive mats used externally by the system builder The AS is especially intended for use in automatic mode during normal program execution The AS is by passed when the operating mode selector is in the MANUAL or MANUAL FULL SPEED position
277. ges 10030 All axes commutated 10031 All axes calibrated 10032 All rev counters updated 10033 All axes synchronized 10034 Axis not commutated 10035 Axis not calibrated 10036 Rev counter not updated 10037 Axis not synchronized 10040 Program loaded The task s has loaded a program or program module The free user space was i bytes before this operation and i bytes after 10041 Program erased The task s has erased a program 10043 Restart failed The task s can t restart 10044 Program Pointer updated The task s could have changed the PP pos 10045 System restarted An already installed system was restarted 10046 System restarted in cold mode First start after installation 10047 Background task s refuse to start Ps 10048 Background task did stop The task s stoped without reason Ps 16 26 10049 Protected area not finish A power fail did occur in the middle of a protected area for the task s Ps 10050 Execution cancelled The restart will clear the execution in task 16s of a s 10051 Event routine error The task s could not start the specified system event routine Ps The routine is either unknown to the system or unlinkable Check Insert the routine in a system module or correct the program 10052 Regain start A regain movement has started 10053 Regain ready The regain movement is ready 10060 Test of enable chain The enable
278. gging not permitted Jogging cannot be done in this mode Check Release the joystick and enabling device and repeat Check also active mechanical unit User s Guide BaseWare OS 3 1 System and Error Messages 60008 Tool mass undefined Jogging cannot be done if the used tool has an undefined mass Check Enter a value for the mass into the tooldata for the used tool 60009 Unsynchronized robot The robot or external axis are unsynchronized Check Synchronize robot or external axis 60010 Orientation error Orientation in s is unnormalized Check Check orientation value 60011 Parameter faults Loading of parameters in Ps cannot be fulfilled For reason see Ps Check Copy the file Ps to a floppy and examine reasons using an ordinary text editor 60012 No Parameters loaded There are no parameters in Ps Check Check the file s using an ordinary text editor 60013 Jogging not permitted Jogging of mechanical unit is not possible Unit is not activated Check Activate the mechanical unit 60014 Disk is full No info is saved in Change Log about the parameter change because no space available on disk Check Try to delete files or reorganize your disk i 16 87 System and Error Messages 60015 PP cannot be set PP cannot be set to routine s because it has parameters Check Make a routine which call s or remove the parameters 60016 PP
279. gnals connected to the robot Misc Miscellaneous other windows i e the System Parameters Service Production and File Manager windows 4 IS Stop Stops program execution Contrast Adjusts the contrast of the display Menu keys Press to display menus containing various commands Function keys Press to select the various commands directly User s Guide 5 7 Starting up uHo7 IS e m 5 8 Motion Unit Press to jog the robot or other mechanical units Motion Type Press to select how the robot should be jogged reorientation or linear Motion Type Axis by axis movement axis 1 3 2 axis 4 6 Incremental Incremental jogging on off List Press to move the cursor from one part of the window to another normally separated by a double line Previous Next page Press to see the next previous page Delete Deletes the data selected on the display Enter Press to input data Up and Down arrows Press to move the cursor up or down Left and Right arrows Press to move the cursor to the left or right User defined keys How to define these see Chapter 12 System Parameters User s Guide 6 1 Entering text using the teach pendant User s Guide Starting up When naming files routines data etc text can be entered using the teach pendant As there is no character keyboard available the numeric keyboard is used in a special way see
280. gram file name including mass memory unit to be 12 23 System Parameters loaded is also defined in this dialog e g flp1 PROGRAM1 PRG Not valid during program execution ResetEstop Resets the emergency stop The robot can then be set to the MOTORS ON state AckErrDialog Acknowledge the error dialogue on the teach pendant i e the same operation as pressing OK on the teach pendant Several input signals can be assigned the same system actions but several system actions may not be assigned to the same signal 1 Allowed in both manual and automatic mode To delete a system action e Select the signal to be deleted e Press X The system action assigned to this signal is then deleted but the signal itself remains defined 3 9 Defining system outputs The output signals can be assigned a specific system status In this case they will auto matically be handled by the robot If the signal has not already been defined define its name in the normal way See Defining input and output signals on page 12 e Choose Types System Outputs All defined system outputs will be displayed see Figure 12 File Edit Topics Types System Parameters IO Signals System Outputs Name Status 1 3 do8 MotorOn do9 MotorOff progrun CycleOn Add Figure 12 Output signals can be assigned specific types of system status 12 24 User s Guide System Parameters e Select the syste
281. gt operators must have equal type Check the operand types 40052 Instruction error Task 16s RETURN with expression only allowed in function Check In a procedure or trap the RETURN instruction must not specify a return value expression Remove the expression 40053 Instruction error Task 16s RAISE in error handler must not have an expression Check A RAISE instruction within an error handler can only be used to propagate the current error and may therefore not specify an error number Remove the error number expression 40054 Type error Task 16s Different dimension of array type i and aggregate i Check Make sure that the number of expressions in the aggregate is the same as the dimension of the data array 40055 Type error Task 16s Assignment target type 18s is not value or semi value type Check The type of the data to be assigned a value must be a value or semi value type Data of non value types may only be set by special type specific predefined instructions or functions User s Guide Base Ware OS 3 1 40056 Type error Task 16s Type 18s for left operand of gt or lt gt operator not value or semi value type Check The and lt gt operators may only be applied to expressions of value or semi value type If comparisons are to be made special type specific predefined functions are needed 40057 Type error Task 16s Type
282. gument is to constitute an expression with several components e g reg reg2 or regl gt 5 or a string value e g Producing part A For more information see Expressions on page 18 e If desired choose Next to change the next argument e Choose OK to confirm Note You can also use Copy and Paste to change arguments Note Any changes in an active position instruction except for ModPos will be valid first for the next execution of the instruction To get an immediate result choose Special Move PP to cursor 8 5 Adding optional arguments Optional arguments of an instruction are not normally included when programming an instruction but have to be added afterwards e Select the instruction that is to be modified e Press the function key OptArg If you are in the Program Test window you must first select the whole instruction then press Enter and then OptArg A dialog box appears displaying all arguments that the current instruction can possibly have The arguments not included in the instruction are enclosed within square brackets see Figure 29 e Instruction Arguments 2 9 MoveL Conc ToPoint Speed Time V Zone Z Tool WOb3 Add Remove Cancel OK Figure 29 The dialog box used to add optional arguments e Add an optional argument by selecting the desired argument and pressing Add 8 34 User s Guide Programming and Testing Some argument
283. hat happens on start up or what the teach pendant does and looks like in Chapter 5 Starting up Generally speaking the robot is operated by means of different windows Manual movement see Chapter 6 Jogging User s Guide 2 3 Introduction 2 4 Manual operation of inputs and outputs see Chapter 7 Inputs and Outputs Programming and testing see Chapter 8 Programming and Testing The programming language is clearly described in Chapter 9 The program ming language RAPID For a more detailed description see RAPID Reference Manual Running production see Chapter 11 Production Running Setting system parameters see Chapter 12 System Parameters Copying programs etc see Chapter 13 File Manager Service tools see Chapter 14 Service Calibrating the robot TCP and other coordinate systems see Chapter 10 Calibra tion The program option Screen Viewer is described in Chapter 15 ScreenViewer Chapter 16 contains Error Management and System and Error Messages In Chapter 17 Program Examples a number of programs are built up step by step Here you can learn a little about how to program and also see the instructions in their correct context If you want to find out what a particular menu command does you should refer to Chapter 18 Quick Reference This chapter can also be used as a pocket guide when you are working with the robot If the robot is delivered or upgraded with some extra functionali
284. he current executing instruction is shown in the window see Figure 5 File Edit View Production Info PROG1 Routine 1 Status Running Speed 100 Running mode Continuous 1 2 Executing RAPID instruction MoveL p2 v500 z20 tooll The executing instruction Program Executing __ Figure 5 The current instruction is shown while the program is running User s Guide Production Running 5 1 Restarting after a stop If you wish to restart program execution from where it was interrupted e Press Start The program can also be restarted from the beginning This is described below 5 2 Starting a program from the beginning To start again from the beginning proceed as follows e Choose Edit Start from Beginning File Edit View 2 Start from Beginning e Press OK to confirm The program pointer gt gt will then move to the first instruction in the program e Press Start 6 Stopping the Program Program execution can be stopped by pressing the stop button on the teach pendant see Figure 6 In case of an emergency press one of the emergency stop buttons instead This will cut off the power supply to the robot motors and engage all brakes Figure 6 This stop button is used to stop the program User s Guide Production Running 7 Tuning position e Choose View Position File Edit View 1 In
285. he external axis e Press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Description Notch filter activated Yes if activated No otherwise Notch filter frequency Frequency of speed variation Used when Notch auto mode is set to No Typical value 2x Weld speed Weave length Notch filter width Width of notch filter A higher value increases the width but can also have a negative effect on the performance response of the external axis Recommended value 0 2 Notch auto mode If Yes the notch filter frequency will automatically adjust to the weave frequency according to the formula 2 x Weld speed _ Weave length auto no weave freq This frequency is used in the notch filter when Notch auto mode is set to Yes but weaving is not being used or Rapid Weave is being used Note The default value should only be changed by advanced programmers auto min freq The minimum notch filter frequency when Notch auto mode is set to Yes Note The default value should only be changed by advanced programmers User s Guide System Parameters auto max rel change Factor that sets the maximum instant change in the notch filter when Notch auto mode is set to Yes Note The default value should only be changed by advanced programmers 7 18 Soft servo for external axis Soft servo can be activated for external axis which are configured with Lag control master 0 The beh
286. he list of the installed user screen packages name and size used and the total memory size used see Figure 9 Screen package informations 1 3 SpotTimer 1 00 23 4 used SpotGun 2 01 16 7 used Pallet 2 21 11 6 used Memory 25230 49000 bytes 51 7 used Remove Exit Figure 9 The screen information window User s Guide 15 17 Screen Viewer e Press Remove to remove the selected package e Choose Exit to return to the screen options window 16 The Screen Display The screen display window is accessible only if at least one user screen package has been installed e Press Start in the screen options window A dialog box appears displaying the current screen of the first user screen package installed Four of the menu keys can be user defined and represent the definition of the user screen The menu key View is reserved for displaying the list of the installed packages see Figure 10 View 1 SpotTimer 1 00 2 SpotGun 2 01 3 Pallet 2 21 Figure 10 The screen display window The selection of the different screens of a user screen package to display is made by the menus and the function keys according to the definition of the user screen package installed The selection of a new user screen package is made by the selection of the package in the View menu The current screen of the package selected will then be displayed For more detailed informations on a sp
287. he motors These values are generally updated from the Service window If however they are known they can be specified in the System Parameters window e Choose Topics Manipulator e Choose Types Motor Calib e Select the desired motor and press Enter e Select the desired parameter and change its value Press OK to confirm Parameter Description Name The name of the motor e g motor_1 max 16 characters Calibration offset The position of the motor resolver when it is in the calibration position in radians Cal offset valid Specifies whether the calibration offset is defined Commutator offset The position of the motor resolver when the rotor is in the electrical zero position relative to the stator in radians Com offset valid Specifies whether the commutation offset is defined User s Guide 12 53 System Parameters 7 2 Defining the range of movement and calibration position of each axis e Choose Topics Manipulator e Choose Types Arm e Select the desired arm axis and press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Description Name The name of the arm e g arm_1 max 16 characters Upper joint bound The upper joint limit e g 3 139 for axis 1 in radians 180 3 1416 radians Lower joint bound The lower joint limit e g 3 139 for axis 1 in radians Use check point The name of a check po
288. he operating mode selector eeeeeeeceeeseeeenteeeenee 3 7 T4 Enable device e eepe e a a E T 3 8 Tad Hold to r n Control sssini i i apis etii ii 3 8 7 6 General Mode Safeguarded Stop GS connection sssseseseereeeererrerreereseee 3 9 7 7 Automatic Mode Safeguarded Stop AS connection eeeseseeseeeerereerreeee 3 10 7 8 Limiting the working space ssesssesssesessseessetssersseesseeessseesseesseesseeesseesssees 3 10 7 9 Supplementary functions s sseesssessessseeseeeesstessetsseesseressseesseesseesseesseeessees 3 10 8 Safety Risks Related to End Effectors sesssessseessocesocesoocssoeessccssocesocssoosesseessoe 3 10 Dll E th N D e E EE A A E EEE E E EE yes 3 10 Ol TOOlIS WOrKPi ECE Sises aiia A E a E 3 11 8 3 Pneumatic hydraulic systems 1 1 12 ccedasesssdessuscadendeagannssosencbasnaezeaetsdesanedenseetens 3 11 9 Risks during Operation DisturbanCeSs sseessocesccescocessesssecesocesoossoosesoeessesesooee 3 11 10 Risks during Installation and Service e ssesssocssooesoossoocessecssocesocesooessosessesssoee 3 11 11 Risks Associated with Live Electric Parts cssccssssssssscsscssscsssssssseseeeeees 3 12 12 Emergency Release of Mechanical Arm esssesssesssecssocesocesoosesocessecssocesoossooseoo 3 13 13 Limitation of Liability ssissssssesssisisissssssesisonsssessssssssasoeessstuoosss ioio asa essens sisses 3 13 14 Related Information sesooesoosoesoosoossesssesooesessoesoos
289. he world coordinate system expressed in quaternions q1 q4 Figure 31 illustrates some examples of different values Specifies whether the robot is to be operated in coordination with a track See Defining a track motion with coordinated motion on page 63 Suspended Suspended case case 2 X Y Z 0 1 0 0 X Y Z 0 0 1 0 Figure 31 Some examples of definitions of the base coordinate system 7 12 Defining external manipulators with more than one axis To achieve the best possible performance from an external manipulator a set of data describing its kinematic and dynamic properties among other things must be defined This data cannot be defined in the system parameters but must be read from a diskette If no diskette was supplied with the manipulator the manipulator cannot be coordinated with the robot It can however be defined as a number of separate external axes User s Guide System Parameters e Read the files that define the manipulator See Loading parameters from a diskette or some other mass storage device on page 7 Use the command File Add New parameters e Define the calibration offset name of the mechanical unit etc See Defining external axes on page 63 e Define the base coordinate system as described in Defining an external mechanical unit coordinated with the robot on page 63 7 13 Defining a track motion with coordinated motion e Define the axis in the usual way See Defining extern
290. heck Adjust weave parameters 111011 Weave pattern error Weave pattern tilt angle error PI 2 PI 2 rad Check Adjust weave parameters 111012 Weave pattern error Weave pattern rotation angle error PI 2 PI 2 rad Check Adjust weave parameters 111013 Weave pattern error Weave pattern horizontal offset error 1 1 m Check Adjust weave parameters 111014 Weave pattern error Weave pattern vertical offset error 1 1 m Check Adjust weave parameters 111015 Weave pattern error Weave pattern sync condition left error 0 100 Check Adjust weave parameters 111016 Weave pattern error Weave pattern sync condition right error 0 100 Check Adjust weave parameters 16 103 System and Error Messages 111017 Weave pattern error Forbidden combination of bias and shape Bias only allowed for Zig zag shape Check Adjust weave parameters 111018 Weave pattern error Forbidden combination of bias and width Bias must be less than half the width Check Adjust weave parameters 111019 Weave pattern error Forbidden combination of dwells and cycle length Dwells must be less than cycle length Ramp slope amplitude length is limited Check Adjust weave parameters 112000 Board eipaw error Incorrect digital output length Check Change digital output length to 1 112001 Board eipaw error Incorrect schedule port length Check Change shedule port length to 16s 1
291. hine MoveL v200 fine tooll Go to leave position release Release part MoveL v200 z30 tooll Go to position above part MoveL v500 z30 tooll Go to position above machine 17 4 User s Guide Program Examples 1 6 Starting to process Simple Material Handling Processing starts when the robot pulses an output do Then using the input di the machine informs the robot that the part has been processed and can be fetched Routine process_part PulseDO dol WaitDI dil 1 1 7 Fetching the part from the machine The robot fetches the part from the machine Routine fetch_machine MoveL v500 z10 tooll MoveL v200 fine tooll grip MoveL v200 z30 tooll MoveL v500 z30 tooll 1 8 Leaving the part on the Out feeder The robot leaves the part on the Out feeder Routine leave_part MoveJ vmax z30 tooll MoveL v500 z30 tooll MoveL v200 fine tooll release MoveL v200 z30 tooll User s Guide Comments Pulse output to start machine Wait for the ready signal Comments Go to machine Go to fetch position Grip part Go to position above part Go to position outside machine Comments Go quickly to position near Out feeder Go to position above part Go slowly to leave position Release part Go to position above part 17 5 Simple Material Handling Program Examples 17 6 User s Guide Program Examples Material Handling 2 Mater
292. hoose an alternative using the function keys fields marked with 7 Field Description Name The name of the module a maximum of 16 characters Type Specify whether the module is to be a program or system module e Press OK to end the module declaration 13 4 Changing the name or declaration of a module e Choose View Module e Select the desired module e Press the function key Decl A dialog box appears displaying the module declaration e Make whatever changes you wish to make see Creating a new module on page 56 e Choose OK to confirm the change s User s Guide Programming and Testing 13 5 Reading a program module from diskette or some other type of mass memory e Choose File Open A dialog box appears displaying all modules and programs in the current directory see Figure 49 Open Select a Program or a Module Mass memory unit Massmemory unit flpl lt MODULES e Directory level 4 4 es Go up 1 level CAD_POS Program Module USER System Module BASE System Module Unit New Dir Cancel OK Figure 49 The dialog box used to read modules e If necessary change the mass memory unit by pressing Unit until the correct unit is displayed e Select the desired program module Move up or down in the directory by choosing either up or the desired directory down and press Enter e Choose OK to confirm The specified module will then be read to
293. i agian gies E E E E SeS ETES 33 8 5 Adding optional arguments ss seeeessessessseeesseessstessetsseesseressessseessetsseesseessseeessees 34 8 6 Changing the structure of an IF FOR or TEST instruction s src 35 8 7 Changing the name or declaration of a routine seeeseseseereesrseresresseseresrersersreses 35 8 8 Deleting an instruction or an argument sssessssessesseesseresseetsseessrtsseesseessseeessees 36 oo BA DISARI o eE EE E E E A E 36 8 10 Undo latest action neussninuncnienini sesi isast 36 9 Special Editing FunctionsS ssseccsscssessocosscoccosesoesssoosscoccosccoossosessooossecccosscsosssseesosossssee 37 9 T Search amp replace eiet E a aa E aa E a Eii 37 2 INIT EON ITD a ea N N aa 39 10 Creating DAG ssc cecscscecand cetesilencetin eed OG RE 45 BOLT What 18 lala amesa ess es cde ie Sie Ae ed ata ie eed eS 45 10 2 The Program Data window used to manage data ceeeeeeeeseeeesseceesteeeenaees 45 10 3 CTE ANS new datan are 2c casctanceasuiecen seas csbasenceasacorecssaten ae A R cans RG estes 47 10 4 Creating new array data ecsissiasiicicdeasscasitcntavaseca cate ssdedaes s0ed exceed catasastad nnig u 48 10 5 Duplicate Gata cies hades less ie ecules A ead E INS 50 10 6 Storing position data using the robot cee eeeececsseeceeeeeceeeeeeeeeeeeseeeenteeeeeaeeees 50 10 7 Ro tinedata sscedates cectee senate sue stone a E ue A ERS 50 1 Changin Data seacga ah dacs ccncah es deaeaas cence acdc eaaen d
294. ial Handling 2 1 What the robot does The robot takes parts to and from a machine as in Figure 2 Die casting machine aS In feeder Out feeder Figure 2 The robot serves a machine First the robot fetches a part from the In feeder and places it in the machine When the machine is ready the robot grips the part and places it on the Out feeder The work cycle is repeated until the operator presses a push button Stop production The robot then completes the cycle but does not fetch any new part from the In feeder The robot keeps a record of production statistics it displays the number of parts pro duced during the day on the teach pendant and also at the end of the work day stores this information on a diskette that can be read using a PC 2 2 The main routine The main routine is built up of a number of routine calls which reflect the robot work cycle A digital input signal prodstop defined in the system parameters is used to find out if the button Stop production is depressed The button remains depressed until some one presses it again User s Guide 17 7 Material Handling Routine main start_production WHILE Dinput prodstop 0 DO fetch_part leave_machine process_part fetch_machine leave_part update_cycle ENDWHILE stop_production Program Examples Comments Initialise production for the day Repeat the cycle until the button is p
295. ible to change the speed correction while the program is executing key if it is not already e Select the upper part of the window by pressing the List selected e Select the field Speed see Figure 20 User s Guide Programming and Testing File Edit View Special Program Test WELDPIPE main Speed 50 Running Continuous 1 26 gt Init data counter 0 Go to start position MoveL pstart vfast fine gripper WaitUntil dil 1 Start Set startsignal open_gripper 25 100 Figure 20 The speed can be changed 0 100 e Increase or decrease the speed by pressing the function keys or Correction then takes place in steps of 5 Set the speed to 25 or 100 by pressing the function key 25 or 100 6 4 Choosing the execution mode The program can be run in three different modes continuous cycle one cycle at a time step by step forwards or backwards one instruction at a time Note The execution mode is automatically changed when switching between automatic and manual mode The default set up can be defined in the system parameters Choose continuous or cyclic running as follows e Select the upper part of the window by pressing the List selected e Select the field Running Mn key if it is not already e Choose the program execution mode using th
296. ic input of the position 40652 Axis is moving A Robot axis an external axis or an independent axis is moving Check All Robot axes external axes and independent axes have to stand still E g Use MoveL with Fine argument for the Robot and ext axes And IndRMove for the independent axes 40653 Switch is missing One of the switch parameters s or s has to be defined 40654 Axis is not active The axis is not active or it is not defined Check The mechanical unit has to be activated and the axis has to be defined before this instruction is executed and before a robtarget is saved User s Guide Base Ware OS 3 1 40655 Axis is not independent The axis is not in independent mode Check It is only possible to get the status from an axis in independent mode 40656 Execution error Not possible to set a new scale value for the AO signal Check The internal process that control the output of the AO signal are for some unknown reason dead 40657 Execution error The output of the AO signal are not TCP speed proportional any more The reason could be following Check Use of MoveX between TriggX instr No setup of TriggSpeed in the used TriggX instr The used ScaleLag is too small in relation to actual robot servo lag 40658 Parameter error Parameter s can only be used if parameter s is greater than zero Check Parameter s has effect only in the first TriggX in a seq
297. ich refer to that position data will also be changed 8 3 Tuning position during program execution The tuning command makes it possible to tune the x y and z coordinates of a robtarget during program execution The function is valid only for named robtargets of the datatypes constant and persistent It is not valid for positions represented by and robtargets of the datatype variable The change is also valid in stopped mode e Start with the Program Test window e Press Start The window Program Run Info appears see Figure 25 View Program Run Info PROG1 Speed 50 Running Continuous Executing Figure 25 The window Program Run Info e Select View Position User s Guide 8 31 Programming and Testing The window Program Run Position appears see Figure 26 1 1 View Program Run Position PROG1 Speed 50 Running Continuous Robtarget Tuning Present No Data Figure 26 Window for tuning position during execution e Select the field Robtarget and press Enter e Select the robtarget to be tuned Only robtargets declared in the module chosen in the robtarget dialog are shown To select a robtarget in an other module press Module select module press Enter and continue selecting robtarget e Choose OK or press Enter to confirm the choice The x y and z
298. ieiaeo DD T51 Using aS 5 eas Goss ssi i ina a a e a a ER E ar i 55 16 VO Signals nees ieeeseessroiss ress tsesia We aes Gs ev Wee ee DT 16 1 Programming an I O instruction seseeesseeessessseesseeessetesseessrtsseesseeesseessseesseressessee 57 User s Guide 4 1 Basic operation 4 2 User s Guide Basic Operation Introduction 1 Introduction This manual explains the basics of handling and operating an ABB robot You do not need any previous experience of robots to understand its contents The manual is divided into chapters each of which describes a particular work task and how to go about performing it The chapters complement one another and should therefore be read in the order they appear in the book It is an advantage if you have access to a robot or the PC program Quick Teach when you use this manual but just reading it should help you understand the basic operation of a robot The manual is written to suit a standard installation Differences can therefore occur depending on the configuration of the system Please note that this manual describes only one method of carrying out any of the normal work tasks and if you are an experienced user there may be other methods For other methods and more detailed information see the following manuals The User s Guide is a reference manual with step by step instructions on how to perform various tasks The programming language is described in the RAPID Reference
299. iescces5 sass serscieancsonds decesuvadtuns sas teeeteadengoeteseecemiedes 13 7 se PUI TANG ET A E EEE A E A EE 13 7 A Form tting a Diskette occ ds docs cvecitu ve ddsesscbysdecesgusvsescpeocoducsecseacevesdeckdedesnexcvendsteevesiene 13 7 VA SOP VICE E T T 14 1 1 The Service WIN OW sasictse secisscssecicastovccasivensacasasnrestascasctoseopacacsnens tenseenesacnecseccsaeene 14 3 2 Changing the Current Date and Time sccssssccsssscssssccscsscesssscessccesseccees 14 3 De TODS ETE EA EE TE EETA ETRA 14 4 31 Wat AS aN aoei eaea a a a E aa E EEE E E ERN 14 4 3 2 What types of logs are there sinisiin a A a sees 14 4 do WAC WANG Ad DS E P EE E E E A E E 14 5 DA Viewing a message in AO 55 cciscesssccsseacanes dasddanas esadevesddendancesancedesscecesuscanenee 14 6 3 5 Erasing The contents of AOS tac tas de iee e EE AA 14 6 3 6 Erasing the contents of all logs 0 eee eeeeecsececeecceceeceeceeeeeceeceeceeeeeseeeesaes 14 6 3 7 Updating the contents of a log automatically or by means of a command 14 7 3 8 Avoiding normal error repotts ssessesesseeesseessersseessseessseessresseesseeesseesssees 14 7 3 9 Saving log messages on diskette or some other mass storage device 14 7 4 Calibration ainssi eose esineen asise essa essene ee Snes neS 14 8 41 What is calibrato eo n a A N e a i 14 8 5 COMIC ACION 3 55 sesser issis osise seserian sidos densossdenseddooddekes tiso Dio e soisissa 14 9 Ball Whatis commutat
300. ify the instructions to be included in the list in the Most Common Setup dialog box e Add an instruction by selecting the appropriate instruction and pressing Incl That instruction will then be marked with an x to its left e Remove an instruction by selecting the appropriate instruction and pressing Excl The instruction will still be displayed in the window but the x to its left will disappear e Press Result The instructions included in the pick list are displayed see Figure 52 8 60 User s Guide Programming and Testing Po Most Common Result 1 4 6 Compact IF Setup Move Movey Cancel OK Figure 52 You specify the order of the instructions in the list in the Most Common Result dialog box e Change the order of the instructions using Move and Move v Move moves the selected instruction up one step and Move moves it down one step e When the definition is ready press OK To return to the Most Common Setup dialog box press Setup instead The current Most Common list is automatically chosen as the active pick list The various Most Common lists can be chosen from the IPL2 menu in the Program Instr window Note This definition is stored in the system parameters topic Teach Pendant which should be saved from the System Parameters window 14 2 Default data Global Local You can decide what scope new data of a specific datatype should have by default The scope is either Global reachabl
301. ig plane error In PaintL s Four trig planes s s s and s are defined outside the programmed path Check Change eventdata or reprogram path 130007 Trig plane error In PaintL s Four trig planes s s Ys and s and more are defined outside the programmed path Check Change eventdata or reprogram path 131000 Argument error The argument is not an integer Check Change the argument to an integer 131001 Argument error The argument is not an array Check Change the argument to an array 131002 Argument error The argument is not a persistent variable Check Change the argument to a persistent 131003 Argument error The array argument has too many dimensions Check Change the array to one dimension 16 112 131004 Brush table error Only brush table s is allowed Check Change to allowed brush table 131005 Brush number error Only brush numbers less than or equal to s is allowed Check Change to allowed brush number 132000 Brush number error The brush number is outside the limits for the activated brush table Check Change argument within limits 132001 Brush table error There are no brush table activated Check Activate a brush table User s Guide Base Ware OS 3 1 Program Examples CONTENTS Page 1 Simple Material Handling ee seoesooesoocssscssocesocesoocssseessecssocesooesoocssocessocesocssoosssocsssesssose 3 1 1 Whatthe robot does
302. iggIO TriggInt TriggEquip or TriggSpeed before TriggL TriggC or TriggJ 40634 Reference error Signal reference in parameter s contains unknown signal for the robot Check All signals should be defined in the system parameters and should not be defined in the RAPID program User s Guide BaseWare OS 3 1 System and Error Messages 40635 Reference error Argument reference in parameter 16s is not a entire persistent variable Check Not possible to use record component or array element in arg 16s Only possible to use entire persistent variables for Tool WObj or Load in any motion instructions 40636 Sensor error No measurement from sensor Check Requested data is not available 40637 Sensor error Not ready yet Check Requested function is not ready yet 40638 Sensor error General error Check General error has occurred which is not specifically connected to the requested action Read the block Error log if the function is available 40639 Sensor error Sensor busy try later Check The sensor is busy with an other function 40640 Sensor error Unknown command Check The function requested from the sensor is unknown 40641 Sensor error Illegal variable or block number Check Requested variable or block is not defined in the sensor 16 71 System and Error Messages 40642 Sensor error External alarm Check Alarm from external equipment 40643
303. igure 11 A routine can call another routine e Call up the instruction pick list for the program flow by choosing IPL1 Prog Flow e Choose the instruction ProcCall by pressing the appropriate numeric key You must now specify the routine that is to be called All routines are displayed for this purpose see Figure 12 Select Procedure 1 2 cleangun erroroutl weldseql weldseqz Cancel OK Figure 12 The dialog box used to select procedures e Select the desired routine and press OK If the routine has no parameters the instruction is ready for use if it has parameters indicated by a dialog box will appear in which you specify the parameters of the routine in the same way as you specify an instruction argument 4 2 Program control within a routine The F instruction is used when different instructions are to be executed depending on whether a condition is satisfied or not e g depending on whether an input is set or not User s Guide 9 11 The programming language RAPID Input Condition 1 ue IF dil 1 THEN Instructions executed if dil 1 ELSE Instructions executed if dil 0 ENDIF An IF instruction without ELSE is used when certain instructions are to be executed only if a condition is satisfied If only one instruction is to be executed a Compact IF instruction can be used Compact IF Any condition Any instruction IF regl reg2 Set dol IF
304. il the bump in the path is removed Repeat this procedure for all axes 7 11 Defining the base coordinate system Normally the base coordinate system of the robot coincides with the global coordinate system However the base coordinate system can be moved relative to the global coordinate system Please note that the programmed positions are always related to the global coordinate system and all positions will therefore also be moved as seen from the robot Normally this would be defined from the Service window but if the values are known they can be input from the system parameters e Choose Topics Manipulator e Choose Types Robot User s Guide 12 61 System Parameters e Select the manipulator whose base coordinate system is to be changed e Press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Name Type Base frame x Base frame y Base frame z Base frame ql q4 Base frame moved by Z world X Y Z 1 0 0 0 12 62 Y world X world Description The name of the robot e g robot_1 max 16 characters Robot type not to be changed The X coordinate of the base coordinate system s position in relation to the world coordinate system in metres The Y coordinate of the base coordinate system in metres The Z coordinate of the base coordinate system in metres The orientation of the base coordinate system in relation to t
305. ill be high There is one help operator INV syntax in configuration file inverted The INV help operator can be connected before an in signal actor signal to an AND or OR box which means that the signal is inverted before being checked in the operator box Examples Logical dil do2 AV do26 dol0 In Configuration file EIO_CROSS Lres do26 Lact dil amp do2 amp dol0 Logical dil do2 l do26 dol0 In Configuration file EIO_CROSS Lres do26 Lact dil do2 dol0 User s Guide 12 17 System Parameters dil Q O I INV Invert do2 l do26 e dol0 O In Configuration file EIO_CROSS Lres do26 Lact dil do2 dol0 The actor signals can be both digital In and Out signals There can be 5 actor signals in each condition but there can be several conditions The cross connected signals cannot use Delay or Pulse or any parameters only clean set and reset of digital in and out signals The example below describes a configuration file that has several logical con dition connections 12 18 di2 _ doll do3 amp e dol5 dil2 0O al amp dol4 O do54 C dil3 P do3 1 amp d033 amp _do23 dol7
306. ime from weld start 16s min Check the welding equipment 110025 Current supervision Check Seam name 16s Time from weld start 16s min Check the welding equipment 110026 Wirefeed supervision Check Seam name 16s Time from weld start 16s min Check the welding equipment 110027 Process stopped Check Seam name 16s Time from weld start 16s min Process was stopped by digital input 110028 Torch supervision Check Seam name 16s Time from weld start 16s min Check the welding equipment 110029 Arc ignition failed Check Seam name 16s Time from weld start 16s min Check the welding equipment 16 102 110030 Arc fill ignition failed Check Seam name 16s Time from weld start 16s min Check the welding equipment 110500 Arcitec welddata error Loading or storing welddata failed Max allowed time for operation has expired Check Check external equipment 110501 Arcitec welddata error Storing welddata failed Check Check file path and external equipment 110502 Arcitec welddata error Loading welddata failed Check Check file path and external equipment 110503 Switch is missing One of the switch parameters s or s has to be defined Check Define one of the switch parameters 110504 Value error Argument 16s must have an integer value Check The value of the argument must be an exact integer value The current value has a fraction
307. in ctrl The program server 4 is in control of the motion server Stop the program and perform the command again 20116 Program 5 in ctrl The program server 5 is in control of the motion server Stop the program and perform the command again User s Guide BaseWare OS 3 1 System and Error Messages 20120 System IO in ctrl 20125 Client s in ctrl Specified client is in control of the requested resource program motion 20130 Out of memory in cfg 20131 Unable to read file 20132 Parameters not saved Parameters cannot be saved Probably because disk is write protected or no space available Check Check if disk is write protected or if space on disk is enough 20133 Cannot modify instance DescriptionReason Can t replace instance in line d of file s Check The instance is write protected 20134 Wrong version DescriptionReason The cfg domain version is wrong in file Ps The software is made for version s Check Change the version of the cfg domain 20135 Line too long Description Reason Line d gt d characters Check Reduce the number of characters 20136 Attr out of range DescriptionReason Attribute s is out of range in line d Check Change the value on the attribute 16 29 System and Error Messages 20137 Dublicate inst name DescriptionReason Dublicate name in line d of file s Check Change the name 20140 Motors On rejected Motors On via Sys
308. in org pos is mirrored to pos_m See Figure 36 pos pos_m Object frame wobj3 Figure 36 Mirroring of a routine using one robot To perform this mirroring the mirror frame must first be defined To do this start off by creating a new work object and name it mirror or whatever Then use the three points p1 to p3 to define the object coordinate system with the help of the robot see Chapter 10 Calibration After this the routine org can be mirrored using wobj3 and mirror as input data Mirror example 2 two robots In this case a routine org created on one robot is to be mirrored and used on another robot Suppose that a spot welding robot robot 1 is used for the left side of a car body When the program for the left side is done it should be mirrored and used again for the right side by robot 2 The original program org is programmed relative to a work object wobj1 which is defined with the help of three points A B and C on the left side of the car body using the 3 point method see Chapter 10 Calibration The mirrored program mir is to be related to a corresponding work object wobj1 defined by the corresponding points D E and F on the right side of the car body Wobj1 for robot2 is defined with robot2 using the same 3 point method Note that since the points D E F are reflected images of points A B and C the wobj1 for robot2 will also be mirrored One of the consequences of this is
309. in the plane of the two turning axes of the Orbit station when the turn table is in its calibration position y O A gt X f User coordinate O O system Figure 14 Orbit user coordinate system The coordinate system of the orbit station has its xy plane in the surface of the turntable and the origin is located in the centre of the turntable i e the z axis will coincide with the second axis e Press the Miscellaneous key and select the Service window e Choose View BaseFrame User s Guide Calibration A dialog containing all synchronized mechanical units is shown e Select the mechanical unit and press Enter or Def A dialog like the one in Figure 15 will appear SSS Orbit User Frame Definition Unit ORBIT Point Status 1 3 Negative X Modified Positive X Positive Y ModPos Cancel OK Figure 15 Dialog for definition of user frame for orbit station To record reference points e Activate the mechanical unit and run it to its calibration position i e zero position should be displayed on the teach pendant e Select the first point Negative X e Point out the reference point on the negative x axis with the robot s TCP it is not necessary that the position is on the negative side of the origin but it must be on the negative side rela
310. inate the dialog 13 4 User s Guide File Manager 3 Creating or Moving Files and Directories 3 1 Creating a new directory e Choose File New Directory A dialog will be displayed as in Figure 3 Create directory named DIRNAME Cancel OK Figure 3 The New Directory dialog e Press Enter lt e Enter the new name and press OK Confirm by pressing OK The directory will be created under the current directory 3 2 Renaming a file or a directory e Choose File Rename A dialog will be displayed as in Figure 4 Rename Old directory name WELDINGS New directory name DIRNAME Figure 4 The Rename dialog for a directory e Press Enter e Enter the new name max 8 characters and press OK e Confirm by pressing OK User s Guide 13 5 File Manager 3 3 Deleting a file or directory e Select the desired file or directory e Press Delete X e Choose OK to confirm the deletion You can only delete a directory if it is empty 3 4 Copying files and directories e Select the file or directory to be copied If you select a directory all subordinate directories and files will also be copied e Choose File Copy A dialog will be displayed as in Figure 5 Type of file J7 Copy Program ramldisk PROC1 Current file Copy from To PROC1 Newihioaame _ at ramldis
311. ined increments e Choose Special Increments A dialog box appears displaying the values of the increments for the different motion types see Figure 23 User defined increments Change the values of the variable jog increments used for the different motion types Motion type Value Limits Linear 5 00 mm 0 50 10 0 Robot axes 3 14 deg 0 01 0 20 Reorientation 0 40 deg 0 03 0 50 External axes Same as medium incr Cancel OK Figure 23 The dialog box for specifying the user defined increments e Change the applicable value s and press OK to confirm 2 10 Jogging an unsynchronised axis If the robot or an external unit is unsynchronised it can only move using one motor at a time The working range is not checked which means that the robot can be moved until it is stopped mechanically User s Guide 6 15 Jogging 3 Jogging External Axes 3 1 Choosing external units If you wish to use more than one external unit those units must be chosen from the Jogging window e Set the motion key to choose external units e Select the field Unit see Figure 24 e Using the function keys choose a unit If you are using more than 5 external units and you cannot find the one you want in the function key dialog press Enter and select the desired unit from the new dialog Unit Manip1 1 23 3
312. information about the selected unit press the function key Info The type of signal DI Digital Input DO Digital Output Al Analog Input AO Analog Output The physical channel to which the signal is connected The numbering restarts from 1 for each unit and signal type The scaling between the programmed and physical value of an analog signal see Figure 7 Physical value of the output signal V mA etc Logical Max Logical value in the program Figure 7 Diagram to show how analog signal values are scaled User s Guide Logical max min is the maximum minimum value that an analog input or output can be set to from a RAPID program or from the teach pendant The units are user defined e g meter minute Physical max min is the maximum minimum physical value that can be set on the output or input To obtain the physical limit for a specified unit see the Product Manual If both physical and logical max min are set to 0 the default values for the unit are picked up which are the physical maxi mum and minimum limits The logical and physical is set to the same value which gives an amplification factor of 1 If any of the values is set by the user all four must be defined Therefore make sure that physical maximum is gt physical minimum logical maximum is gt logical minimum Example An analog unit is controlling a current source with an amplification of 50 A V and a max current of 500A The
313. ing and changing an existing one 3 4 Duplicating a routine e Choose View Routines e Select the routine to be duplicated User s Guide 8 11 Programming and Testing e Press the function key Dupl e Specify the new name of the routine in the dialog box that appears e Choose OK to confirm the duplication This creates a new routine that contains the same data and instructions as the original routine 4 Creating new instructions 4 1 Choosing a routine e Choose View Routines e Select the routine to be programmed and press Enter To call up the main routine e Choose View Main Routine To call up a routine that can be selected from the list of instructions e Select the routine that you want to look at e Choose View Selected Routine 4 2 The Program Instr window e Choose View Instr to open the window If you are in the Program Test or Program Data window you can press the function key Instr instead The instructions for the current routine are displayed in the window see Figure 9 8 12 User s Guide Programming and Testing File Edit View IPL1 IPL2 Program Instr WELDPIPE main 1 26 Init data counter 0 Go to start position MoveL pstart v500 fine gripper Instructions WaitUntil dil 1 Start Set startsignal open_gripper MoveJ v500 2z10 gripper Copy Paste OptArg ModPos Test gt Figure 9 The Program Instr
314. ings stored in the log Check Save those modules that are specified by earlier warnings and try another system start 20164 Reconfig failed There are still some unsaved system module Check Read error descriptions in earlier messages Try another system start User s Guide BaseWare OS 3 1 System and Error Messages 20165 PP lost Restart is no longer possible from current position The program has to be started from the beginning 20166 Refuse to save module The module 14s is older than the source at 37s in task 16s 20167 Unsaved module The module 14s is changed but not saved in task 16s 20170 SYS_STOP Program motion stopped along path 20171 SYS_HALT Program and motion stopped with motors off 20172 SYS_FAIL System Failure restart system 20175 Teachpendant fail Teachpendant lost contact this will force Guard Stop 20180 System IO restriction System IO restrictions are active for other clients e g teach pendant or computer link Check Motor on is restricted by System IO MotorOff Program start is restricted by System IO Stop StopCycle or StopInstr 20201 Limit Switch open 20202 Emergency Stop open 20203 Enabling Device open 20204 Operation Key open 20205 Auto Stop open 20206 General Stop open 16 31 System and Error Messages 20207 Backplane Enable open Check 1 Check other error messages for primary fault reason 2 If no other err
315. ining the User Frame for a rotational axis single eeeeeeseeeeseeeeeee 10 17 6 3 Defining the User Frame for a two axes mechanical unit Method 1 10 20 6 4 Defining the User Frame for a two axes mechanical unit Method 2 10 23 T Defining TOONS sis ssvsiisscssissssieocxesesvn sevens cesescacnceon eves vaseneeveucseseves cessevscennssuncessvvcnessenss 10 28 Ti Creating a MEW LOO oyc csassevcdedscessdsasaacsaeadeesaacusnheaeonspavededsdecadeadbavcans Nia 10 28 7 2 Manually updating the TCP and weight of a tool oo eee eeeeeeeeeeneeeneeees 10 29 7 3 Methods of defining the tool coordinate System eee eeeeeseeeeeeeeeeeneeees 10 29 7 4 Using the robot to change the TCP and orientation of a tool eee 10 31 Tod Stationary TOOL pisses cicdcacachedaacsauacdetestesedatasusiad oisssbantaeasiad oaebecats a e aaas 10 33 8 Work Objects and Program Displacements sscssssccssssccsssccssscsssssssseess 10 35 8 1 Genetal oS eGo BG acl ea Tah acre DG ets ett Gad Prat Gaal Satie el hel uth acetates 10 35 8 2 Using Work objects enren a Messen aacaanS 10 36 8 3 Creating a new work object si siccecscesssacssaeavecsusersaesassncadeatesestenavapaceesndeecensecene 10 36 8 4 Manually updating the user and object coordinate system of the work object10 37 8 5 Methods of defining a work object ssssssesesesseessesssseessseesseesseesseessseesssees 10 37 8 6 Using the robot to change the work object ss ssssssesssesese
316. int if any See Defining arm check point on page 58 Use arm load The name of an arm load if any See Defining arm load on page 57 Calibration position The position of the axis when it was calibrated If this value is changed the robot must subsequently be fine calibrated in the Service window See the Product Manual 7 3 Defining supervision level A 12 54 It is possible to change the default supervision levels if a system needs to be more or less tolerant to external disturbances A higher tune factor than 1 0 gives a more tolerant robot system and vice versa with a tune factor lower than 1 0 For instance an increase from the default tune factor 1 0 to factor 2 0 doubles the allowed supervision levels making the robot system more tolerant to external disturbances Decreasing the tune factor to 0 5 gives a system which is less tolerant to external disturbances Increasing the tune factors can reduce the lifetime of the robot e Choose Topics Manipulator e Choose Types Arm e Select the desired arm axis and press Enter e Select the desired parameter and change its value e Press OK to confirm User s Guide System Parameters Parameter Description Jam sup trim factor Tune factor for jam supervision The factor influences the maximum time allowed at zero speed with maximum torque Load sup trim factor Tune factor for load supervision The factor influences the maximum time allowed at non z
317. int is used to define the z direction and one elongator point is used to define the x direction of the tool see Figure 28 TCP j Elongator points Z Figure 28 Using the 6 point method the TCP and all the tool s directions are defined 7 4 Using the robot to change the TCP and orientation of a tool Open the Program Data Types window by choosing View Data Types e Select the type tooldata and press Enter e Select a tool or create a new tool see Creating a new tool on page 28 e Choose Special Define Coord A dialog box appears displaying the points defined by whichever method was used see Figure 29 Tool Coordinates Definition Tool tool4 Method 4 points TCP Point Status 1 4 Approach Point 1 Modified Approach Point 2 F Approach Point 3 Approach Point 4 Desc ModPos Cancel OK Figure 29 The robot can be used to define the tool coordinate system The status can be defined as follows Status Meaning No position defined Modified Position modified User s Guide 10 31 Calibration To choose a definition method Before you start modifying any positions make sure the desired method is displayed See Methods of defining the tool coordinate system on page 29 e Select the field Method and press Enter e Choose a method and press OK To record Approach Points Select the first point Approach Point 1 e Jog the robot as close
318. ion a load data Joad is defined which describes the load held by the gripper The best possible motion performance is achieved if the correct load is always specified As the gripper grips and releases parts several times during the course of the program it is best to set up separate routines for this which can be called by the program Routine grip Comments Set gripper Grip the part WaitTime 0 3 Wait 0 3 s GripLoad load1 Specify that there is a load in the gripper Routine release Comments Reset gripper Release the part WaitTime 0 3 Wait 0 3 s GripLoad LOADO Specify that there is no load in the gripper 1 4 Fetching a part from the In feeder A part is fetched from the In feeder As the robot cannot go straight from the previous position Out feeder it performs a joint movement to the first position Then it uses linear movement to achieve good path accuracy Routine fetch_part Comments MoveJ vmax z50 tooll Go quickly to position near In feeder MoveL v1000 z30 tooll Go to position above part MoveL v200 fine tooll Go slowly to grip position grip Grip part MoveL v200 z30 tooll Go to position above part 1 5 Leaving the part in the machine The robot leaves the part in the machine and then leaves that area so that the machine can be started Routine leave_machine Comments MoveJ vmax z50 tooll Go quickly to position outside machine MoveL v500 z10 tooll Go to mac
319. ion 2565 e a a a T E RE 14 9 6 Frame Definitions sse ccosednceatsecseacesssonesessiocascanconsecarseseonesienssocneseontesooueaneseess 14 9 1 9 Page 7 Two Axes Definition sessoesocsoesoossccssesoesoossessoesoossossoesoossossoesoossoessessossosssesesssso 14 9 8 Obtaining information on the robot system ssesssecssocesooesoocssscessecesooesoossssessse 14 9 9 Backup and Restore sseoessscoccssssecesescscssoossssooecesosecessoccsessoosessocssssssesesssessssseesss 14 10 9 L Perform a Bae KUD a 2 a Gee RG E Aaa A Ns 14 10 9 2 Perform a Restore e csica tals sdets nnana n A A Maasai 14 11 10 Perform a Restart sessoesossoesooesossoesoosoossossoesocesosssssoossosssessossosssessossosssessssssssse 14 11 Eu ea DAA E E E EE LOM l PE BETS E K S CR A E E E TE l 12 The ScreenViewer WindoW sescossecsessoesoossessoesocesossoesooesossoesooesosssesoossosssessss 15 3 13 Th Screen OptionSisisssssscesessissesirssiinsessseisssrsossssosoissonossassesesvissresesscsesssise asss LD4 14 The Screen Loading sesssessseossececoceccossoocssececooscooseosossocossocesosecosssssesssesssssssssse 15 4 15 The Screen Information eessesooesossoessesooesesssesoossosssesoossocssessossocssessossoossesssssse 15 4 16 The Screen Display cc cescssesccsssevecesesessesssesvonsssavesscnsessnsessvenvsvessvevensstesvasesveesvssenaevs LD 16 Error Mana cement oieciccsccccessccec ccs vecccciecicessccacscccessiceesteccssicvevsdscetsev
320. ion for the respective joystick movements as shown in Figure 33 1 for x axis 2 for y axis and 3 for z axis The signs denote a positive or negative direction of the motion for a positive joystick deflection sideways down Figure 33 Joystick deflections Parameters Coordinate system World down rot side World coordinate system Base down rot side Base coordinate system Tool down rot side Tool coordinate system Wobj down rot side Object coordinate system St tool world down rot side World coordinate system when using stationary tool User s Guide 12 79 System Parameters 12 80 St tool base down rot side Base coordinate system when using stationary tool St tool tool down rot side Tool coordinate system when using stationary tool St tool wobj down rot side Object coordinate system when using stationary tool Reorientation jogging e For each coordinate system specify the desired direction of rotation for the respective joystick movements as shown in Figure 33 1 for rotation around the x axis 2 for y axis and 3 for z axis The signs denote a positive or negative direction of the motion for a positive joystick deflection Parameters Coordinate system World down rot side World coordinate system Base down rot side Base coordinate system Tool down rot side Tool coordinate system Wobj down rot side Object coordinate system St tool world down rot side World coordinate system when using stationary tool St tool bas
321. ion function must be specified 40266 Reference error Task 16s 16s is not a data type name object 16s Check The specified name identifies an object other than a type 16 65 System and Error Messages 40267 Reference error Task 16s 16s is not a value data type object 16s Check Only record components alias types variables and VAR mode parameters may be of semi value or non value type 40268 Symbol definition error Task 16s Missing value conversion function for 16s Check A value conversion function must be specified for a semi value type 40269 Symbol definition error Task 16s Not enough memory for value of data 16s Check More memory required 40270 Type definition error Task 16s Private type 16s can only be semi value or non value type specified value i Check Change the value type class 40271 Type definition error Task 16s Private type 16s size must be multiple of 4 specified value i Check All RAPID types must have a size that is a multiple of four Change the specified type size 40272 Type error Task 16s Persistent type mismatch for 16s Check There is already a persistent data with the same name but with another data type Rename the persistent or change its data type 16 66 40273 Reference error Task 16s Unknown data type name 16s for 16s Check There is no data type or other object
322. ion of the tool is active robot robot s position Figure 33 Example of a motion instruction User s Guide 4 29 Selecting a Program Basic Operation 4 30 User s Guide Basic Operation Starting the Program 8 Starting the Program You are now going to start the program you just opened It should first be run step by step using reduced velocity then continuously The program consists of four motion instructions and includes positions near the robot s calibration position see Figure 34 Figure 34 The robot s calibration position AN Before starting the program move axis 5 manually with the joystick downwards about 45 For information on the various robot axes see Chapter 3 2 1 Press the Program window key and a window like the one in Figure 35 will appear you have already reached this stage if you have come directly from Chapter 7 File Edit View IPL1 IPL2 Program Instr EXERCISE main 1 4 MoveL WSO tinen COSIO MoveL v300 fine tool0 k r MoveL v300 fine tool0 f MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 35 The Program window User s Guide 4 31 Starting the Program Basic Operation 2 Press the Test function key The window in Figure 36 appears EX ERCISE main View Special 100 Continuous fine tool0 fine tool0 fine to
323. ipulator e Choose Types motion system e Press Enter e Select CPU equalisation and change its value e Press OK to confirm When CPU equalisation is increased it can also be beneficial to increase the system parameter Queue time Queue time Increasing Queue time will make the system more tolerant to uneven CPU loads The User s Guide 12 85 System Parameters drawback is that the robot will react more slowly when jogging and when stopping a program in execution However the emergency brake is not affected Also the accuracy of sensor process e g Weldguide and Conveyor tracking may be impaired e Choose Topics Manipulator e Choose Types motion system e Press Enter e Select Queue time and change its value e Press OK to confirm Note that the real queue time is a multiple of a sample time related to dynamic resolution If the value of the parameter Queue time is not an even multiple of dynamic resolution then the controller will automatically use a queue time as close as possible to the given Queue time Process update time Process update time determines how often the process path information is calculated This information is used for path following in Conveyor Weldguide and Rapid Weave for example Decreasing Process update time will improve accuracy but also increase CPU loading Increasing Process update time will decrease the CPU loading Note When running programs whe
324. irror all positions mentioned above in the mirror plane i e the mirrored position will be located symmetrically on the other side of the plane relative to the original position The mirror plane is always the xy plane of an object frame used for mirroring This object frame is defined by a work object data e g with the name MIRROR_FRAME The work object MIRROR_FRAME uses as all work objects two frames for defining the object frame the user frame and object frame User s Guide 8 39 Programming and Testing The object frame is defined relative to the user frame and the user frame is defined relative to the world frame Usually the user frame is set equal to the unity frame and in such a case the object frame is defined relative to the world frame see Figure 34 The mirror frame must be stated in the mirror dialogue mirror plane s o original point world frame e mirrored point Figure 34 The mirror plane Work object All positions which are to be mirrored are related to a specific work object frame This means that the coordinates of the robtarget data are expressed relative to this work object frame see the figure above Furthermore the mirrored position will be related to the same work object frame In the dialogue before mirroring this specific work object must be stated This work object will be used as the reference frame for all variables that are to be mirrored IMPORTANT Be sure to state the sam
325. irrored Mirroring data only affects the initialization value i e any current value will be ignored This means that if a robtarget variable has been defined without an init value this variable will not be mirrored The mirroring works as follows e The new routine is scanned for any local robtarget data declared inside the routine with an init value All such data s init values are mirrored e Then the new routine is scanned for any statement with one or more arguments of type robtarget e When such a statement is found the following actions will take place If the argument is programmed with a reference to a local variable or a constant this argument will be ignored since it has already been mirrored as described above If the argument is programmed with an immediate robtarget data shown with an asterisk then this value will be mirrored directly If the argument is programmed with a reference to a global variable persistent or a constant defined outside the routine with an init value then a duplicate is created and stored in the module with a new name the old name ending with _m The init value of this new data is mirrored and after that the argument in the statement is changed to the new name This means that the module data list will expand with a number of new mirrored robtarget data Error handlers or backward handlers if any in the routine are not mirrored Mirror plane The mirror function will m
326. is positional range is also specified in Supervision To activate forced gain control for an external axis the system needs to be booted with the service option e Choose Topics Manipulator e Choose Types Lag control master 0 e Select the lag control master corresponding to the external axis e Press Enter e Select the desired parameter and change its value Press OK to confirm Parameter Description Forced control active Determines whether forced gain control is active for this joint If set to Yes Affects forced ctrl in Supervision should normally also be set to Yes for this joint see below Forced factor for Kp The forced factor for Kp if forced gain control is active Forced factor for Ki The forced factor for Ki if forced gain control is active Rise time for Kp The rise time for forced Kp The default values for the forced factors and rise time are recommended but can be changed if necessary e Choose Topics Manipulator e Choose Types Supervision e Select the supervision corresponding to the axis that should should not affect forced gain control e Press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Description Affects forced ctrl Determines whether this joint affects forced gain control Forced on pos limit The upper position limit for forced gain control Forced off pos limit The lower position limit for forced gain
327. is a small chance that there is not enough time to make a proper close down at power fail ure The robot will in this case tell the user that a restart is not possible 1 1 Errors on start up During the entire start up sequence the robot functions are checked extensively If an error occurs it is reported as a message in plain text on the teach pendant and recorded in the robot s event log For more information on troubleshooting see the Product Manual 2 The Operator s Panel The functions of the operator s panel are described in Figure 2 MOTORS ON button and indicating lamp lt Operating mode selector Emergency stop ___ CO lt _ Duty time counter If pressed in pull to release Indicates the operating time for the manipulator released brakes MOTORS ON Continuous light Ready for program execution Fast flashing light 4Hz The robot is not calibrated or the revolution counters are not updated NB The motors have been switched on Slow flashing light 1 Hz One of the safeguarded space stops is active NB The motors have been switched off Figure 2 The operator s panel is located on the front of the cabinet 3 Selecting the Operating Mode The operating mode is selected using the operating mode selector 3 1 Automatic mode production mode When the robot is in the automatic operating mode it is essential that nobody enters the safeguarded space around it Carel
328. iseee asooo tots Ossos 2 3 3 How to Rea this Mantal ssscsssssscsisssccssessorsssssrvsrssosseosrossssssesoisorsosvosss eosssesasss 2 3 3 1 Typographic conventions sssssessseeesseessseessesssessseeessseesseesseesseeessessseessrese 2 4 4 Reader s Comments e seessesooesesssesossocesessoesoosseessesooesosssessossosssesoossosssessossosssesssse 2 5 EET i TE A E E E 3 1 DCO Tall aisaseresnis cussievaccunsiuassbupsacesenndusbsssaaceahsoinusoabaaseuavetxssosesoutivendoynesseteasesaronmeuasoens 3 3 Led Introduction niinen a a decode te E E E a wens 3 3 2 Applicable Safety Standards eesoessocessecssecesocesooessoessscessocesocesoosssocsssesesocesocsso 3 3 3 Fire Eytinguishih 5 5csec5tcocevcdesdepocscanesavcueaseucceauscavcnsanencscnneenecseansavasenesoneneaveneeuoane 3 4 4 Definitions of Safety Functions sseessoesssesssecesocesocesoosessesssecesocesooseoosesoesssecssocee 3 4 5 Safe Working Procedures ssecssesseccsosecooceooocsococsocccoseccoccoooesooocsosecosecssesoseesosee 3 5 Soll Normal Operations sissie a Hes tee de en tea ean a n 3 5 6 Programming Testing and Servicing ccccccsscccssssscssscssssscssssscssssssssssseees 3 5 7 Safety Fun ei Ons sissccescssedsscviescesaacsecessieacensevouassawssaiunas a E e ra eias 3 6 7 1 The safety control chain of Operation sesseesesseseeseseresressersresressersresreseese 3 6 Pid Emergency Stops acna cet te lee ela ee R a S E R 3 7 7 3 Mode selection using t
329. ision The motion supervision parameters do not require a restart when modified Use the following procedure to change the motion supervision system parameters e Choose Topics Manipulator e Choose Types Motion Sup e Select the desired instance usually IRB and press Enter e Select the desired parameter and change its value Press OK to confirm User s Guide 12 55 System Parameters 12 56 Parameter Description Path col detect Turn the collision detection ON or OFF for program execution also modifies the load and jam supervisions Jog col detect Turn the collision detection ON or OFF for jogging also modifies the load and jam supervisions Path col detect level Modifies the supervision level for the collision detection for program execution by the specified percentage value also modifies the load and jam supervisions A large percentage value makes the function less sensitive Jog col detect level Modifies the supervision level for the collision detection for jogging by the specified percentage value also modifies the load and jam supervisions A large percentage value makes the function less sensitive 7 5 Defining teach mode speed When there is a requirement to monitor manual mode with reduced speed lower than 250 mm s this can be achieved by changing the teach mode maximum speed e Choose Topics Manipulator e Choose Types Motion system e Select the desired sy
330. iskette Basic Operation Massmemory Save Program as name Name EXERCISE pe ad Massmemory Unit flpl DEMO 1 1 Go up one level Unit New Dir Cancel OK Figure 61 Dialog box for Save Program as 4 Press Unit to choose the type of mass storage if it is not already chosen flp1 should appear on the third line of the window see Figure 61 5 Press Enter to enter an optional name The text input dialog box in p p 2 Figure 62 then appears 7 8 9 Enter Name aeeoa EXERCISE 4 5 6 536 1 2 3 456 P 123 GH z aig JK 0 Some of the characters obtained by pressing lt Ea Cancel OK different numbers Figure 62 Window for entering text You can now see five groups of characters Each group is represented on the numeric keyboard the layout of the keyboard corresponds to the layout of the characters You can move between the various groups using the lt and gt function keys the selected group is indicated with squares both above and below it see Figure 62 Use the Delete key to delete the name that is displayed or any errors you may type 6 Now give the program a new name When you have entered this press OK The window in Figure 63 appears 4 52 User s Guide Basic Operation a Save Program as Name XXXXX Massmemory Unit fl
331. isplayed in the window The log shows the error code number a brief description of the error and the time the error was registered If you highlight one of the errors in the log the window will then be updated with the appropriate error code number reason and category The Check function key can be used to get help on how handle a specific error If you press OK the error message window will disappear Using the joystick try to manually operate the robot outside its operating area You will then see an example of an error message User s Guide 4 39 Errors Basic Operation 4 40 User s Guide Basic Operation Switching the robot off 12 Switching the robot off If you are going to continue with the rest of the exercises you can skip this chapter the gripper and peripheral equipment So before switching the robot off check first that the equipment and any people in the area will not come to any harm All output signals will be set to zero when the robot is switched off This may affect 1 If the program is running stop it by pressing the Stop push button on the teach pendant 2 After you have done this switch off the mains switch The robot s memory is battery backed and is thus not affected when the system is switched off User s Guide 4 4 Switching the robot off Basic Operation 4 42 User s Guide Basic Operation Changing a Program 13 Changing a Program The following chapters are intended to
332. iss osso besss os senose esesta baois 7 User s Guide 13 1 File Manager 13 2 User s Guide File Manager File Manager The File Manager is used to copy or transfer files change the name of a file create directories on diskettes or other mass storage devices print files format diskettes 1 Program Data Storage Programs and data are stored as normal PC text files These can be saved and restored to from a diskette or an internal RAM disk The diskette is a standard 3 5 High Density 1 44 Mbytes DOS formatted diskette Note Before saving programs and data the diskette should be formatted in the robot or in a PC Pre formatted DOS diskettes will not always operate satisfacto rily Note The diskettes must never be stored inside the cabinet as the information on them can be destroyed due to heat and magnetic fields The internal RAM disk is a special part of the robot s memory and can be used in the same way as a diskette A file can be a program data created by the program or system parameters and the like stored in some sort of mass storage Directories are used to group files together to achieve a memory unit that is more struc tured For example test programs in one directory and production programs in another see Figure Directories Files ee SERVICE TESTPROG lt TESTI PARTA PARTB PRODPROG PARTC PARTD Figure 1 The files can be stored in directorie
333. istance value measured between incoming phases 12 67 System Parameters 12 68 Phase inductance H Stator phase inductance e Choose Types Motor_calibration and define the calibration and commutation offsets as described in Defining the commutation offset and calibration offset of the motors on page 53 Commutation Normally commutation does not need to be implemented because the motors supplied by ABB are precommutated with the commutation value 1 5708 Input commutation offset for an uncommutated motor 1 Ensure that the motor is not affected by large external torques gravity and friction 2 Connect a DC power supply to the motor S phase T phase R phase not connected 3 Feed in as large a current as possible with regard to the max permissible currents of the motor 4 The motor will now assume the commutation position 5 Commutate the motor from the Service window Calibration offset can be updated by moving the axes to their calibration positions and then fine calibrating from the Service window e Choose Types Max operational cycle and specify the characteristics of the drive system at its maximum usage Parameter Description Torque abs max Max allowed torque Nm Speed abs max Max allowed motor rotational speed radians s e Restart using File Restart Define activating relays if any are connected The external drive units can be activated via signals from the robot When a unit is ac
334. it 71106 dsqce344 board failure DescriptionReason Faulty or re started IBS board Board internal error code d Check 1 Check above error see IBS manual Firmware Service and Error Messages 2 Update board firmware 3 Replace InterBus S board 16 96 71107 InterBus S bus failure DescriptionReason Lost contact at address d d Check 1 Check InterBus S bus at the above address 2 Restart the system 71108 InterBus S module failure DescriptionReason The unit s at address d d reported internal unit error Check 1 Check the unit at the above address 2 Restart the system 71109 InterBus S module failure DescriptionReason Incompatible definition of unit s at address d d Check 1 Check the I O system parameters 2 Restart the system 71110 InterBus S module failure DescriptionReason Illegal address s on unit s Check 1 Change the address in the system parameters I O unit configuration 71111 Wrong product code DescriptionReason The product code of unit s doesn t compare to any known id code Check 1 Change product code in configuration 2 or check module 71112 Unequal of units DescriptionReason Definied number of units is different to the one binded to the board Check 1 Change unit definition in the configuration 2 or check the modules User s Guide Base Ware OS 3 1 71113 IBS user command failure DescriptionReason Warning due to d
335. it can be used However depending on the configuration of the robot there is usually a number of predefined data Data can be defined as constants variables or persistents The value of a constant can only be changed manually A variable can also be changed by the program but its initialisation value is automatically set when the program is read from diskette or the like the program is started from the beginning i e from the first instruction in the main routine the program pointer is moved to the beginning of a routine by choosing Test Move PP To Routine or to the beginning of a program by choosing Test Move PP To Main A persistent can be described as a variable whose initialisation value is constantly updated so that it corresponds to the current value Thus its value is not changed when the program is started from the beginning If the program is output to a diskette the new initialisation value is stored 10 2 The Program Data window used to manage data e Choose View Data to open the Program Data window The window displays all data of the type last selected The current values are also displayed see Figure 39 User s Guide 8 45 Programming and Testing File Edit View Data Special Program Data WELDPIPE Data type num In System Name Value Local Module 3 7 counter_a 12 X WELDPIPE Data gt counter_b 20 WELDPIPE regl 1 X USER reg2 0 x USER reg3 0 USER reg4
336. ive unit joint s Check Restart start controller Replace drive unit 39202 Drive System Error Watchdog reset from drive unit joint s Check Restart start controller Replace drive unit 39203 Drive System Error 15V out of limit on drive unit joint s Check Check 15V from power supply Replace drive unit 39204 Drive System Error Too many consecutive communication synchronization errors on drive unit joint s Check Restart start controller Replace drive unit Replace drive unit right to the one reporting the error Replace Robot Computer Board 39205 Drive System Error Internal Hard Ware SoftWare error on drive unit joint s Internal error code s Check Restart start controller Replace drive unit 16 45 System and Error Messages 39206 Drive System Error Glitch on short circuit detector on drive unit joint s 39207 Drive System Error Short circuit detected on drive unit joint s 39208 Drive System Error High temperature WARNING on drive unit joint s 39209 Drive System Error High temperature ALARM on drive unit joint s Check Allow system to cool down before restart 39210 Drive System Error Over temperature on drive unit joint s Check Allow system to cool down before restart 39211 Drive System Error High temperature on transistors on drive unit joint s Check Allow system to cool down before restart
337. k SERVICE 5 18 anf Go Up One Level PROCO Program Content of PROC52 Program 9 BROCS bergen Modni destination directory SDATA Program Modul Unit Cancel Copy Figure 5 The dialog for copying files or catalogues e Specify the name of the new file by selecting the field To and press Enter If you do not specify a name the copied file directory will be given the same as the original e Specify the destination unit first part of At field by pressing the Unit function key If you do not specify a unit the same unit that was used originally will be used e Specify the destination directory latter part of At field by selecting the lower part of the window Select the desired directory and press Enter If you do not specify a directory the same directory that was used originally will be used e Choose Copy to start copying 13 6 User s Guide File Manager 3 5 Moving files and Directories e Select the file or directory that is to be moved e Choose File Move A dialog will be displayed as in Figure 6 Type of file 7 Move Program Current file From ramldisk PROC1 Move from To PROC1 New file name 7 lat ramldisk SERVICE 5 18 os Go Up One Level PROC31 Program Content of PROC52 Program destination directory PROCS Program Modul SDATA Program Modul Unit Cancel Copy Figure 6 The dialog for moving of
338. k joint definition 116002 Track max path corr error Check Check joint definition 116003 Track communication error Check Check hardware 117001 Welding equipment error EPROM checksum error in Welddata Unit detected at power up Check EPROM in Welddata Unit is faulty Running with this error gives unpredictable result Exchange EPROM 117002 Welding equipment error Internal RAM read write error in Welddata Unit detected at power up Check At least one memory cell in internal microprocessor memory failed in read write test Running with this error gives unpredictable result Replace Welddata Unit 117003 Welding equipment error External RAM read write error in Welddata Unit detected at power up Check At least one memory cell in external microprocessor memory failed in read write test Running with this error gives unpredictable result Replace Welddata Unit 117004 Welding equipment error DC supply voltage for 5 Volt regulator in Welddata Unit has been down Check Indicates that there is a problem in power supply but the function is probably not affected Check incoming power supply to Welddata Unit User s Guide BaseWare OS 3 1 System and Error Messages 117012 Welding equipment error Welddata Unit CAN controller for internal bus is in WARNING state Check Change data several times or reset welding equipment with power switch If the error do not disappear check bus connections and or
339. l Term at JOR SUNG oie as aos ode ea pcace cactus AE E E T 21 6 2 Pine positioning inscris aadeasasdaeadevensedais soaeaasedossanes EA A ees 23 7 Selecting a PO DEAN sissies eases enon catuseceadesneacevanyeawscaioseecsesteoencasam son gevetineeeinetees DO Fol Using th AMIS PTO SPAIN sreci uiste aeo i ieSe 25 S Starting th PrOgraM sssevsscssvsvssessevecessvsvesescnasvanssesavecesnavevecesvevedenvave sesenseveresvsvecssesenveceeres OL 9 Stopping the Progr anni sceg si iecetieiectancatiareenseticr eevee hare nO OD 10 Automatic MOU G s sssssssssisessrosssssssssssrsssoisosssssssssssoos ssocsrossossose sbsssotssssssossseosoosssssss sssssss OT DU TOOTS E EE E E E T TE b 12 Switching the ropot OFF ses scsiecsccaisivscsvcassnescessonssstibvassovcessonstesvansevenssavsasevssbsrevensveteesseseas AL 13 CHANGING a Pr ralsssssesssicsssssscesresssdesisosoisesrssasdoosotssossssossepeosvisessssissok ossos sisie A E3 E Modifying positions 22 asses en tet dee e a e a s aa 43 13 2 Cha sing AT OUTS TIES n r a ree tea e a a e A s 45 T33 Adding INS UCT OUS soncesracdat lt a ccanlaecssmudasncateat angdateasyaccned a aE LEES 46 13 4 Programming a Gel ay ascese tedensteavabeccesndesdbarosesanesobene 48 14 Storing the Program on Diskette ccssccsssscssssscssssccsssccssssscsssscssssccesseccssssscsssers OL 1 ol SEOMIN SOM GISK CUS ioc yatee feccsasanseny eed a oy kes atacand esas Seen aReaeees 51 15 Printing Program S si resenseer s oiran roes isoa e
340. lace measure board 33404 Over writing drive sys Over writing of input data from drive system f Check Reload system Replace robot computer board Replace drive unit 33405 Timeout mea system Contact lost with measurement system f Axis computer stopped due to transmission timeout Check Check connections from cabinet to measurement board s Replace measurement board or robot computer 33406 Timeout drive sys Contact lost with drive system f Axis computer stopped due to transmission timeout Check Check connections from cabinet to drive unit s Replace drive modeule or robot computer 33407 Access violation Access violation of measurement system Check Reload system Replace robot computer board User s Guide Base Ware OS 3 1 33408 Access violation Access violation of drive system Check Reload system Replace robot computer board 33409 Access violation Access violation of R6 calculation unit Check Reload system Replace robot computer board 33410 Access violation More than one status in R6 cleared simultanously Check Reload system Replace robot computer board 33411 Unknown error interrupt Unknown error interrupt from the axis computer Check Restart system Replace robot computer board 33412 Clock error Axis computer driver clock failure Main computer is not responding on request Check Reload system Replace main computer board 33413 Loopback e
341. ld coordinate system and then jogging the robot in these directions Note The elongator points must be defined with the same orientation as the last approach point used User s Guide 10 29 Calibration TCP Elongator points Z Figure 25 Elongator points for a tool s orientation If you only want to define the TCP only the world fixed tip is needed If you only need a definition of the orientation in the z direction the elongator will only point to z The following methods are supported 4 point TCP Four approach points are used to define the TCP The orientation will be set according to the wrist coordinate system see Figure 26 TCP Z N Figure 26 Using the 4 point method only the TCP is defined The tool direction will correspond to the wrist coordinate system 4 p TCP ORIENT NOT SET The same as 4 point TCP but the orientation will not be changed 5 point TCP amp Z Four approach points are used to define the TCP and one elongator point is used to define the z direction of the tool The x and y directions will be as close as possible to the corresponding axes in the wrist coordinate system see Figure 27 TCP Elongator point Z Figure 27 Using the 5 point method the TCP and the tool s z direction are defined The x and y directions are set automatically by the robot 10 30 User s Guide Calibration 6 point TCP amp ZX Four approach points are used to define the TCP one elongator po
342. le must be reachable in every warm start e g ram1disk base sys Storage Built in or loaded A built in module is not visible it will not occur in the list of modules and cannot be removed from the program window see Developer s Manual Loaded is the default behaviour TextResource If Storage is set to Built in it is possible to use a national language for routine names for example This parameter should be 0 as English is used for the RAPID language see Developer s Manual User s Guide 12 41 System Parameters Shared If Storage is set to Built in it is possible in a multitask system to install the module so it and all its objects will be reachable from all tasks This parameter should then be set to YES These objects are also called Intertask Objects see Developer s Manual The default behaviour is NO The files ram1disk base sys and ram 1disk user sys are predefined and should not be removed but the contents of user sys may be modified The file ram1disk base_mt sys should always be defined for any additional tasks 5 7 Defining multitasking Available when the option Multitasking is installed The various tasks are defined with name priority and execution behaviour Changes to any item in this menu will force the system to restart the program handling part of the system at the next warm start All user programs will be erased and all task modules specified in the configuration will be
343. led in accord ance with the safety requirements set forth in the standards and regulations of the coun try where the robot is installed The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly People who work with robots must be familiar with the operation and handling of the industrial robot described in applicable documents e g Users s Guide and Product Manual AN The diskettes which contain the robot s control programs must not be changed in any way because this could lead to the deactivation of safety functions such as reduced speed 1 1 Introduction Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and peripheral equipment This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot In the Product Manual nstallation instructions are provided for connecting safety devices between the robot and the peripheral equipment 2 Applicable Safety Standards The robot is designed in accordance with the requirements of ISO10218 Jan 1992 Industrial Robot Safety The robot also fulfi
344. lict with another program symbol with the same name Due on that fact the signal will not be mapped to a program variable Check Rename the signal in the IO configuration 3 Hardware error messages 31108 Error in serial channe Error in serial channel f Check 1 Check communication parameters 2 Replace robot computer board 31114 Bus error Bus error when accessing LED on main computer Check 1 Replace main computer board 2 Replace robot computer board User s Guide Base Ware OS 3 1 31115 Error in serial channel 1 Received data not equal to transmitted data Check 1 Check communication parameters 2 Replace robot computer board 31117 Parity error channel 1 Check 1 Check communication parameters 2 Replace robot computer board 31118 Framing error channel 1 Check 1 Check communication parameters 2 Replace robot computer board 31119 Noise error channel 1 Check 1 Check communication parameters 2 Replace robot computer board 31130 Port error Check Replace robot computer board 31131 SYSRESET did not fire Replace VME bus boards 1 Check Robot computer 2 Check other VME bus boards 3 Check backplane 31132 Error in serial channel 2 Received data not equal to transmitted data Check 1 Check communication parameters 2 Replace robot computer board 31133 Overflow serial channel 2 Check 1 Check communication parameters 2 Replace robot computer board 31134
345. lower part press one of the function keys Data Func or Content first User s Guide 8 19 Programming and Testing Data gives a list of all user defined data of the selected data type Func gives a list of all functions of the selected data type Content gives an intermediate dialog where data of a new data type can be chosen in the same way as the IF instruction for example You can also choose to view user defined or system defined data or both v denotes the current choice see Figure 16 SSS Select datatype VUser data 1 num System data 2 signaldi 3 bool A rt Add Remove Cancel OK Figure 16 Dialog box for choosing data types Editing an expression Move the cursor using the arrow keys The content of the list will change so that it corresponds to that selected The function key Content changes to Insert see Figure 17 EN Expression reg2 lt counter_b 1 2 counter_a counter_b reg1 reg2 reg3 reg4 Text Func Insert Cancel OK Figure 17 The dialog box for editing an expression Replace what has been selected by selecting the desired choice in the lower part of the box and pressing Enter 4 You can make an addition to an expression by pressing the function key Insert An underscored blank _ will then be inserted before the cursor and the function key Insert will change to Content see Figure 18 8 20 User s Guide Programming and Testing EE
346. ls the ANSI RIA 15 06 1992 stipulations User s Guide 3 3 Safety 3 Fire Extinguishing AN Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot manip ulator or controller 4 Definitions of Safety Functions Emergency stop IEC 204 1 10 7 A condition which overrides all other robot controls removes drive power from robot axis actuators stops all moving parts and removes power from other dangerous func tions controlled by the robot Enabling device ISO 11161 3 4 A manually operated device which when continuously activated in one position only allows hazardous functions but does not initiate them In any other position hazardous functions can be stopped safely Safety stop ISO 10218 EN 775 6 4 3 When a safety stop circuit is provided each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit It is necessary to reset the power to the machine actuators before any robot motion can be initiated However if only the power to the machine actuators is reset this should not suffice to initiate any operation Reduced speed ISO 10218 EN 775 3 2 17 A single selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot Interlock for safeguarding ISO 10218 EN 775
347. m Function User level Confirm 1 5 Launch Operator No ModPos Operator Yes Edit Program Delete Instr Delete Object Conf Start Operator No Programmer Yes Programmer Yes Operator Yes Figure 25 Authorise Program Function Launch ModPos Edit Program Delete Instr Delete Object Conf Start Description To authorise the opening of the window To authorise modification of a position To authorise changing of the program To authorise the deletion of any instruction in a RAPID routine To authorise the deletion of any RAPID objects e g routines modules or data Only confirmation If set to No the program execution will always start from the program pointer PP e To change user level and or confirm see Defining authorisation on page 47 6 4 Activation of Limited ModPos Function If the Limit ModPos function is active only a limited deviation from the original posi tion is allowed when the ModPos key is pressed to modify a position The limited deviation concerns both the linear distance and the orientation e Choose Topics TeachPendant e Choose Types Modify Position Now the current type of ModPos function will be displayed ModPos or LModPos e Press Enter e Select the desired parameter and change its value e Press OK to confirm User s Guide 12 49 System Parameters 12 50 Parameter Type Tuning In Auto Mode Max Trans Max Rot Max Ext
348. m output to be changed and press Enter lt or add a new one by press ing Add e Define the name of the signal and the system action assigned to it Press OK to confirm The following types of system status are available System status MotorOn MotOnState MotorOff MotOffState CycleOn EmStop AutoOn RunchOk TCPSpeed Error PFError MotSupTrigg MotSupOn RegDistErr Description The robot is in the MOTORS ON state If the robot system is not synchronised the output will start flashing The robot is in the MOTORS ON state The output is stable i e no flashing The robot is in the MOTORS OFF state If the safety chain is broken the output will start flashing The robot is in the MOTORS OFF state The output is stable i e no flashing A program is executing The robot is in the Emergency Stop state The emergency stop must be reset before the robot can be set to the MOTORS ON state The robot is in automatic mode The run chain is not broken An analog signal that describes the speed of the TCP The logical value of the signal is specified in m s e g a speed of 2000 mm s corresponds to the logical value 2 The scaling factor for the physical value is specified in the system param eters of the corresponding signal The robot program execution has been stopped due to an error If an error occurs when a program is not executing this output will not be set A power failure error has
349. matic model wrist centre frame tool frame User xX Robot base Y aie X X The accuracy of the robot i e how well the tool frame will coincide with the pro grammed position is normally independent of the accuracy of the various coordinate systems This is true however only if the same coordinate systems are used as when programming the robot pointing out all positions with the robot repetition accuracy If the coordinate systems are changed making it possible to displace the program then the accuracy is dependent on every single link in the chain This means that the accu racy is directly dependent on the calibration accuracy of the various frames This is even more important for off line programming In the following chapters an overview will be given of the steps to be taken to calibrate and define the robot and the different coordinate systems mentioned above 10 4 User s Guide Calibration 2 Coordinated axes 2 1 External axes general All external axes are handled in mechanical units This means that before an external axis may be moved the mechanical unit to which it belongs must be activated Within a mechanical unit the different axes will be given a logical name from a to f In the system parameters these logical axes will be connected to the external axes joints For each joint a motor and a drive unit is defined Different joints may share the same motor and drive unit Two or more mechanical
350. med positions are decreased The number of simultaneously controlled axes is increased Using coordinated interpolation Using Weldguide Using Conveyor tracking Using RAPID controlled path correction Using Multitasking with computationally demanding RAPID programs Reorienting with a small or no TCP movement It is important to use a path resolution value which is as small as possible in order to achieve a high path resolution also at high speed Keeping Path resolution small can also give shorter cycle times if the cycle contains many stop points and the move instructions following these stop points have low speed e Choose Topics Manipulator e Choose Types motion system e Press Enter e Select Path resolution and change its value e Press OK to confirm There is also a RAPID instruction called PathResol which affects the resolution of the path For more information about the instruction see RAPID Reference Manual User s Guide System Parameters Prefetch time Prefetch time affects the point in time at which the controller starts to plan for the motion through a fly by point If the planning time is too short a fly by point will become a stop point This generates an error called 50024 Corner path failure Increasing the parameter Prefetch time may solve the problem when the planning time is too short because of high CPU loading However it will not solve the problem when the e
351. mm error from rtp1 DescriptionReason Not possible to deliver the received message Check 1 Check the communication flow 71078 Comm error from rtp1 DescriptionReason The response from the device has a non valid frame sequence Check 1 Check for noise on the serial line 16 94 71079 Pulsing group output DescriptionReason Pulsing group output not allowed Check 71080 Unit type table full DescriptionReason The number of unit types must not exceed d Check 1 Reduce the number of unit types 71081 Physical table full DescriptionReason The number of physical signals must not exceed d Check 1 Reduce the number of physical signals 71082 Signal table full DescriptionReason The number of user defined signals plus panel signals must not exceed d Check 1 Reduce the number of signals 71083 Symbol table full DescriptionReason The number of symbols must not exceed d Check 1 Reduce the number of symbols 71084 Triggr table full DescriptionReason The number of Subcribed signals must not exceed d Check 1 Reduce the number of Subcribed signals 71085 Unit table full DescriptionReason The number of boards must not exceed d Check 1 Reduce the number of defined boards User s Guide Base Ware OS 3 1 71090 Invalid unit type DescriptionReason The vendor id read from unit s doesn t match value in unit type configuration Configuation
352. mputer board 32301 Memory error MAIN COMP Check Replace main computer board 32302 Memory error MAIN COMP Check Replace main computer board 32303 Memory error MAIN COMP Check Replace main computer board 32305 Type error MEMORY EXPANS Check Replace memory expansion board 33150 Axis Computer Int Error Axis computer was stopped with hw interrupt due to interrupt error Check Reload system Replace robot computer board 33158 Axis Comp Driver Clk fail Axis computer driver clock failure Main computer is not responding on request Check Reload system Replace main computer board 33159 Manual Mode Speed Warning Manual mode speed exceeded for the joint connected to axc channel f Check Check for correct load mass definition Check controller parameters on external axes Check for robot singularity Replace drive unit User s Guide Base Ware OS 3 1 33201 Axis cpu Read Error Error in reading from axis computer driver Axis computer driver did not return correct number of bytes Check Check system configuration Reload system Replace robot computer board 33202 Axis cpu Write Error Error in writing to the axis computer driver Axis computer driver did not return correct number of bytes Check Check system configuration Reload system Replace robot computer board 33203 Axis cpu ioctl Error Error in ioctl to the axis computer driver Fail to execute ioctl command Check Restart
353. n an easy to access list of your most frequently used signals by specifying the contents of the Most Common list e Choose File Preferences All signals will be displayed Those included in the Most Common list will be marked with an x to the left of their names see Figure 2 7 4 User s Guide Inputs and Outputs as Most Common Setup Name Type 4 64 x dil DI di2 DI x gripl DO x grip2 DO x grip3 DO x grip4 DO progno GO welderror DI Result gt Excl Cancel OK Figure 2 You specify the signals to be included in the list in the Most Common Setup dialog box e To add a signal select an appropriate signal and press Incl This signal will then be marked with an x to the left of its name e To remove a signal select an appropriate signal and press Excl This signal will remain in the window but the x to the left of the signal name will disappear e Press Result The signals included in the Most Common list will then be displayed see Figure 3 EE Most Common Result Name Type 4 5 dil DI gripl DO grip2 DO grip3 DO grip4 DO Setup Move Move y Cancel OK Figure 3 The order of the signals in the list can be specified in the Most Common Result dialog box e You can change the order of the signals using the Move keys The selected signal moves one step at a time e Define the signal and press OK if you want to return to the Most Common Setup dialog box press Setup first
354. n calibration 2 Gun position User s Guide BaseWare OS 3 1 System and Error Messages 120067 Gun command not allowed Motion forbidden during an action Check 1 Wait until the end of the action before ordering new one 120070 Gun drive fault fault detected by drive unit Check 1 drive unit leds 120075 Gun encoder error Check 1 Encoder wring 120084 Gun wrong pos computed inconsystency between revolution counter and encoder value Check 1 Drive and swit measurement bus 2 Make a gun first init 120085 Gun revol counter error Check 1 Encoder wiring 120090 Gun not calibrated No calibration done or lost Check 1 Make a gun first init 10 Paint error messages 130001 Equipment error Paint process and motion stopped Check Check the paint equipment 130002 Equipment error The argument is not a persistent variable Check Change the argument to a persistent 130003 Trig plane error In PaintL s One trig plane s are defined outside the programmed path Check Change eventdata or reprogram path 16 111 System and Error Messages 130004 Trig plane error Trig plane error In PaintL s Two trig planes s and s are defined outside the programmed path Check Change eventdata or reprogram path 130005 Trig plane error In PaintL s Three trig planes s s and s are defined outside the programmed path Check Change eventdata or reprogram path 130006 Tr
355. n error Messages accessed sescesccecosecdcbusdesedues sdssdesdoscdcuvedcosdedcosgueeteade teevenseceesiecrsccdeie DO Operator error Messages 6 lt csicrsiccevessasssntenscccdsevenccovceneseve cesvecevevencson sens ceonceevecsycuseesocenessnes OO TO amp Communication error MESSAGES cccscccssscssssccssssccssssccssssccssssccssssssssssssssssccees 7 2 Arcweld error MESSAGES ides scacccesensccessissvcdeusincradesdssdedesnssvadssnssddadsisscddesseaseastuens sses siseste OO PANNA YN bh Ww NY Spotweld error messages sessseessecccoseccosecoosscoccocecooscooocosoossocccocccooseosossocesssccsosecsssessessse J2 10 Paint error messages ssecesssooesssooeeesoocoessocesssooceesooecesssecesosoossssoossssooesesoseessssesssssoosssse JJ User s Guide BaseWare OS 3 1 16 23 System and Error Messages 16 24 User s Guide Base Ware OS 3 1 1 Operational error messages 10002 Program reset The task s has been rewound to its start point 10005 Program stopped The task s has stopped The reason is that Ps 10007 Program started The task s has start to execute s 10008 Program restarted The task s has restart to execute s 10009 Work memory full No memory left for new RAPID instructions or data The task is s Check Save the program and then restart 10010 Motors off state 10011 Motors on state 10012 Guard stop state Runchain opened by any safety guard except the em
356. n pick list by choosing IPL1 Various or Mathematics e Choose the instruction by pressing the appropriate numeric key You must now specify the data to be changed All the various data are displayed for this purpose see Figure 16 PEE Select datatype 1 num e g regl 5 2 bool e g flag1 TRUE 3 robtarget e g pl p4 4 E Cancel OK Figure 16 The dialog box used to select data type e Select the desired data type and press Enter Alternatively you can use the numeric keyboard to select the figure in front of the desired data type If the desired data type is not found among the three predefined types choose alternative 4 for more types The data types that have already been used in the program will now be listed in the lower half of the box see Figure 17 To view all the data types press the function key All pi Select datatype 1 num e g reg1 5 2 bool e g flagl TRUE 3 robtarget e g pl p4 Bite SS 1 11 dionum jointtarget loaddata num robtarget speeddata All Cancel OK Figure 17 The dialog box shows data types used in the program e Choose the desired data type and press Enter A dialog box will appear in which you can define data that is to be changed see Figure 18 User s Guide 9 15 The programming language RAPID 9 16 Instruction Argument lt VAR gt lt EXP gt
357. n the agility of the robot The robot is calibrated on delivery The position of the robot axes is determined using a resolver and a counter that counts the number of resolver revolutions If the robot is correctly calibrated it is automati cally able to calculate the current position on start up Calibration is carried out in two stages Calibration of resolvers fine calibration the axes are placed in their specific calibration positions and the current resolver values are stored For information on how to do this see the chapter on Repairs in the Product Manual Update of revolution counters the correct motor revolution for the calibration is defined the axes are placed close to their calibration positions and the revolution counters are updated The position of an external axis is determined using sync switches The same method used for the robot can be used 3 2 Viewing the calibration status e Press the Miscellaneous key and select the Service window e Choose View Calibration This window displays an overview of the status of all the mechanical units in the robot system see Figure 1 10 6 User s Guide Calibration File Edit View Calib Service Calibration Unit Status 1 4 Robot Synchronized Calibration gt manip1 Synchronized status Manip2 Synchronized Trackm Synchronized Figure 1 The Service Calibrate window shows whether or not the robot system is calibrated
358. n to the world coordinate system In order to define a robot base frame you need a world fixed tip within the robot s work ing range and optionally an elongator attached to the tip If the robot is mounted on a track or similar the track should be in its calibration position The calibration procedure consists of a number of positionings for the robot s TCP to a reference point The ref erence point s coordinates in the world coordinate system must be known The coor dinates must be stated before the calibration can be done The following positions on the world fixed tip device are involved in the calibration the tip itself with known coordinates in world used when defining the base frame translation one point on the elongator defining the positive z direction for the world coor dinate system one point on the elongator defining the positive x direction for the world coor dinate system Elongator point Z Xw Yw Zw Robot base World X Figure 3 Robot base frame definition points Elongator point X World fixed tip device When the necessary conditions are fulfilled the definition of the robot base frame can be performed Please observe that in the case of a track mounted robot the track must be in the calibration position before the base frame of the robot may be defined e Press the Miscellaneous key and select the Service window e Choose View BaseFrame A dialog containing all syn
359. nal number 2 Change the length User s Guide Base Ware OS 3 1 71045 Filter specification err DescriptionReason Signal s No filter time can be specified for this type of signal Check 1 Set filter time to 0 or remove the statement 71046 Scaling error DescriptionReason Signal s No scaling can be done Check 1 Remove the scaling statements 71049 Parameter Invert error DescriptionReason Signal s This type of signal can t be inverted Check 1 Only digital signals can be inverted 71050 Cross signal not digital DescriptionReason Signal s Is not a digital signal Check 1 Only digital signals can be cross connected 71052 Cross table full DescriptionReason The sum of different FROM signals added with total sum of TO signals must not exceed d Check 1 Reduce the number of signals 71053 Connection to board down DescriptionReason Can t access the board due to communication is down Check 1 Check the communication cable to the board 2 Check if the board is switched off User s Guide BaseWare OS 3 1 System and Error Messages 71054 Wrong signal type DescriptionReason Signal s The type of signal is wrong Check 1 Change the type 71055 Invalid signal name DescriptionReason Symbol s is not defined Check 1 Change the symbol name above 71056 Power fail restore full DescriptionReason Symbol s could not be setup
360. nd Ti and the axis will not be fully utilised Ti I time speed loop The integration interval constant of the velocity control e g 0 2 A low value gives low steady state error and better path following If Ti is too small the axis will overshoot and the response will be oscillatory Tuning strategies for Lag Control Master 0 Specifying the Inertia If the No or Spd configuration is used the parameter Inertia should be set to 0 If the Trq configuration is used the total mass moment of inertia should be calculated and entered under Inertia This is only recommended for experienced users The inertia is given by Inertia Inertia 4 yi Transm gear ratio Inertia Motor Inertia Break Initial tuning of Kp Kv and Ti Set Kp to 5 e Select Ti based on the mass moment of inertia of the external axis Ti should be in the range from 0 1 for very light axes J 0 3 kgm to 0 5 for the heaviest axes J 12 kgm A typical value is 0 3 e Increase Kv to its highest value until the axis starts to vibrate oscillate or a clear vibration can be heard from the axis either during motion or when stationary The axis velocity supervision may also indicate speed failure When you reach the unstable point divide Kv by 2 e Increase Kp in increments of 0 5 for the fastest response time until the first signs of overshooting are observed Then subtract from Kp If you observe overshooting at a later time reduce Kp to an even lower valu
361. ndow it will look the same as it did the last time you worked with it User s Guide 4 19 Working with Windows Basic Operation 4 20 User s Guide Basic Operation Jogging the Robot Using the Joystick 6 Jogging the Robot Using the Joystick You can move jog the robot using the joystick on the teach pendant This chapter describes how to jog the robot linearly i e in a straight line and step by step to make it easier to position the robot exactly known as incremental jogging 6 1 Linear jogging 1 Make sure that the operating mode selector is in the lt 250 mm s position A as shown in Figure 14 oO A Figure 14 The maximum speed during manual operation is 250 mm s 2 Check that the Robot motion unit and the Linear motion type are selected see Figure 15 ez Motion unit L Motion type KIS Figure 15 Motion keys LEDs shows the current settings With the Motion unit key you can choose between operating the robot or some other unit connected to the controller using the joystick Select the robot for this exercise With the Motion type key you can choose the way you want the robot to move when you use the joystick during manual operation You can choose linear movement reorientation of a particular end effector axis by axis movement group 1 axes 1 3 group 2 axes 4 6 We will use linear motion for the purposes of this exercise
362. ne name after the program name Now you can create and change routine data in the same way as for program data 11 Changing Data 8 50 11 1 Viewing and possibly changing the current value e Select the desired data in an instruction e Choose Edit Value A dialog box will appear displaying the current value see the example in Figure 44 For more detailed information on the meaning of the various components see the appropriate data type in the RAPID Reference Manual User s Guide Programming and Testing EE Current Data value 2 17 gun1 tooldata robhold TRUE bool tframe pose trans pos x i 0 0 num _ Data types y 0 0 num Z 0 0 num rot orient ql 1 0000 num TRUE FALSE Cancel OK Figure 44 The dialog box used to change values e Change the value by selecting the desired field then Choose an alternative using the function keys Specify the value directly using the numeric keyboard e Choose OK to confirm the change You can also open the dialog box as follows e Choose View Data e Select the desired data If you wish to view data of a type other than that displayed choose Data Datatypes and select the desired data type e Press Enter or choose Data Value Continue as above when the dialog box appears 11 2 Changing data names or declarations e Choose View Data e Select the desired data If you wi
363. ng next search make sure that TCP is moved back to the start position of the search path Check If no repositioning is done before restart of circular search movement that can cause damage might occur 40510 Security warning The move instruction can t restart due to security problem Try to move the PP 40511 Parameter error The parameter 16s in 16s is specified with a negative value Check The parameter must be set positive 40512 Missing ext axis value Some active external axis have incorrect or no order value Reprogram the position 40513 Mechanical unit error Not possible to activate or deactivate mechanical unit 40514 Execution error Too far from path to perform StartMove of the interrupted movement Check Position the robot to the interrupted position in the program 40515 Type error Task s Illegal data type of argument for parameter s 16 68 40516 Value error Task s Illegal value of argument for parameter s 40517 Search error s No search hit or more than search hit during stepwise forward execution The search instruction is ready and next instruction can be executed Check Note that no position has been returned from the search instruction 40518 Type error Ps 40590 Parld error 40s 40s Check 40s 40591 Argument error Unknown type of parameter identification 40592 ParId Program Stop Any type of program stop during load ide
364. nipulator e Choose Types Trafo e Press Enter e Select Power max and change its value Press OK to confirm Cable length The lengths of the power cables are set to 30 m on delivery If shorter cables are used this parameter can be changed Choose Topics Manipulator e Choose Types Cable e Press Enter e Select Length and change its value Press OK to confirm User s Guide 12 87 System Parameters 12 88 User s Guide File Manager CONTENTS Page 1 Program Data St ra te sesssiiissrescsorsssessisoss tessons coseno s ies ded ete ene rae 3 2 The FileManager WindoW e ssooesesooccesoccesssoosessoocessooecesooccesssoosessooesesooecesssecessscossssosee 4 2 1 Ch osinga directory maneni nin a a a a E anaes 4 2 2 Viewing file inf rmate aa a a aaa GR eer 4 3 Creating or Moving Files and DirectoriesS ssesssesssecesocesoosssocessecssocesocesoocesseessecesosee 5 Sel Creatine anew directory anes aero rete eae tle en Dae een oee NERE gt 3 2 Renaming a fle ora directory essersi sise iets cuavated yes t shes a a 5 3 3 Deleting a file OF directo yrei sensei a ai 6 3 4 Copying files and directories 32 ccsccessiccedsasvcssceesnaceuendeaseatesevsadeeanacsdintedessnedensactennds 6 3 9 MOVIE TUES ONO Directories on 25 sive casera E EE EOE RRR 7 3 6 Printing Hle renine onni e E E A E a e E EA A 7 4 Formatting a Diskett seisscssssssssssssssiosssssssesictsossesstssr vostes s
365. nning Mode Settings The default set up for the running mode can be defined for the program window man ual mode and the production window automatic mode e Choose Topics TeachPendant e Choose Types Running Mode e Press Enter e Select the desired parameter and change its value Press OK to confirm User s Guide 12 51 System Parameters Parameter Description Operating mode Manual or Automatic mode Running Mode Running mode Continuous or Cycle when starting the robot in this mode or switching to this mode 12 52 User s Guide System Parameters 7 Topic Manipulator The Manipulator topic contains parameters associated with motion control in the robot and external axes e g The commutation offset The calibration offset The working space limits e Choose Topics Manipulator Do not change Transm gear ratio or other kinematic parameters from the teach pendant or a PC This will affect the safety function Reduced speed 250 mm s Regarding available parameters please note the following Some parameters described here require the boot sequence service to be available when making changes see the Product Manual Installation and Commissioning chapter Installing the Control Program It may also be convenient to make a backup and restore it later on see Chapter 14 Service Backup and Restore in this manual 7 1 Defining the commutation offset and calibration offset of t
366. not be present for more than one parameter from a list of parameters that exclude each other 40193 Execution error Task 16s Late binding procedure call error i Check There is an error in the procedure call instruction See previous message for the actual cause 16 61 System and Error Messages 40194 Value error Task 16s Division by zero Check Cannot divide by 0 Rewrite the program so that the divide operation is not executed when the divisor is 0 40195 Limit error Task 16s Exceeded maximum number i of allowed RETRYs Check The error correction performed before the RETRY instruction is executed is probably not enough to cure the error Check the error handler 40196 Instruction error Task 16s Attempt to execute place holder Check Remove the place holder or the instruction containing it or make the instruction complete Then continue execution 40197 Execution error Task 16s Function does not return any value Check The end of the function has been reached without a RETURN instruction being executed Add a RETURN instruction specifying a function return value 40198 Value error Task 16s Illegal orientation value AOs Check Attempt to use illegal orientation quaternion value 40199 Value error Task 16s Illegal error number i in RAISE Check Only error numbers in the range 1 99 are allowed in the RAISE instruction 16 62 40200 Limit err
367. nt s has at least one data component with negative value Check Set all data components in argument s to positive values User s Guide BaseWare OS 3 1 System and Error Messages 40603 Argument error Argument s has a not allowed negative value Check Set argument s to positive 40604 Argument error Argument Tool has undefined load of the tool Check Define the actual load of the tool before use of the tool for jogging or program movement 40605 Argument error Argument Tool has negative load of the tool Check Define the correct load of the tool before use of the tool for jogging or program movement 40606 Argument error Argument Tool has at least one inertia data component with negative value Check Define all inertia data components ix iy or iz to actual positive values 40607 Execution error Not allowed to change run mode from forward to backward or vice versa during running a circular movement Check If possible select the original run mode and press start to continue the stopped circular movement If not possible move robot and program pointer for a new start 40608 Argument error Orientation definition error in s Check All used orientations must be normalized i e the sum of the quaternion elements squares must equal 1 16 69 System and Error Messages 40609 Argument error Argument WObj specifies a mechanical unit with too long name Check
368. nt inserted Corner zone is changed to fine point Too many consecutive Move instructions without fine point 50138 Arm check point outside The robot has reached the limit for arm check point Check Use the joystick to move the involved joint into the working range again 50139 Arm check point outside Jogging was made in wrong direction when arm check point was out of working range Check Use the joystick to move the joint in opposite direction 50140 Payload too large Heavy payload caused static torque limit to be exceeded on joint s Check Check and reduce payload for arm and or wrist Reduce joint working range to decrease static torque due to gravity 50141 Jog or Speed error 1 Jogging error 2 High speed error 3 Robot too close to singularity Check 1 Jog with incremental movement 2 Reduce the programmed speed 50142 Manipulator config error Configuration of the manipulator failed Check Check the parameter values under System parameters Manipulator User s Guide BaseWare OS 3 1 System and Error Messages 50143 Robot axes config error Actual configuration is not the same as ordered and or reorientation of joint 4 6 is too large Check Use SingArea_Wrist ConfL_Off modify position or insert intermediary point 50144 Disp frame uncertain Calibration of displ frame uncertain 1 Wrong TCP 2 Ref points inaccurate 3 Ref points badly spaced Check If estimated error
369. nt instruction pick lists IPL1 Common Prog Flow Various Motion Settings Motion amp Process Io Communicate Interrupts Error Recovery System amp Time Mathematics SOMO WAANTA UF WDN FE 3 3 2 Menu IPL2 shows different instruction pick lists IPL2 1 Most Common 1 2 Most Common 2 3 Most Common 3 Motion Set Adv Motion Adv Ext Computer Multi Tasking RAPID Support Service oOmoHtoanuw amp 18 10 User s Guide Quick Reference The Program Window 3 4 Window Program Routines File Edit View Routine Special Program Routines WELDPIPE Routines In Module Name Type 4 6 cleangun erroroutl givedist num Return value Routines Tan of a function weldseql weldseq2 New Decl Dupl Data gt Test Create a new routine Duplicate Change the declaration View routine data User s Guide 18 11 The Program Window 3 4 1 Menu Routine Routine Quick Reference 1 Routine Data 2 Instructions Error Handler Backward Handler o In Module 6 In System 7 Add Error Handler 8 Add Backward Handler Command Routine Data Instructions Error Handler Backward Handler In Module In System Add Remove Error Handler Add Remove Backward Handler 3 4 2 Menu Special Special Mirror Command Mirror 18 12 Used to create a new routine see page 8 10 view the instructi
370. ntax errors are logged in a separate file 40323 Load error Task 16s Syntax error s in header in file 40s Check The source file to be loaded contains syntax error in the file header Correct the source file The syntax errors are logged in a separate file 40324 Load error Task 16s Keywords not defined in specified language file 39s Check Cannot load RAPID source code in the national language specified in the file header User s Guide BaseWare OS 3 1 System and Error Messages 40325 Load error Task 16s Not enough heap space Check There is not enough free memory left 40326 Load error Task 16s Parser stack full file 39s Check The program is too complex to load 40327 Load error Task 16s Not current RAPID version file 39s Check Cannot load RAPID source code of the version specified in the file header 40351 Memory allocation error Task 16s Failed to allocate hash table use linear list 40352 Memory allocation error Task 16s Failed to update persistent expression keep old one 40501 Timeout Ps s 40502 Digital input break Ps os 40503 Reference error Device descriptor is Ps 40504 Parameter error Ps 40505 File access error s s 40506 System access error Ps Ps 16 67 System and Error Messages 40507 Limit error s 40508 Wrong orientation value in s 40509 Search warning Jos Before performi
371. ntification is not allowed Check Start the identification procedure from beginning again 40593 ParId Power Fail Power Fail during load identification results in faulty load result Check Restart the program execution again with same run mode without PP move for load identification from beginnig 40594 ParId user error Error resulting in raise of PP to the beginning of the parameter identification procedure Check Start the identification procedure from beginning again User s Guide Base Ware OS 3 1 40595 Argument error Unknown type of load identification 40596 ParId Program Stop Any type of program stop during load identification is not allowed Check Restart the program execution again for load identification from beginnig From old PP pos and with same run mode if try to move PP within program list 40597 ParId Speed Override Speed override not 100 per cent Check Change the speed override to 100 Restart the program execution again for load identification from beginnig 40600 Argument error No WObj specified for movement with stationary TCP Check Add argument WObj for actual work object If not movement with stationary TCP change argument Tool to robot holds the tool 40601 Argument error Undefined if robot holds the tool or the work object Check Check if mismatch between argument Tool and argument WObj for data component robhold 40602 Argument error Argume
372. ntil TPWrite the start signal is given by the operator TPReadFK reg Put part on feeder and press start Start ENDWHILE MoveJ pl vmax z50 gripper1 Go quickly to position above part MoveL p2 v100 fine gripper1 Go to grip position grip_part Grip part MoveL pl v200 z30 gripper1 Go to position above part 2 6 Leaving the part in the machine The robot leaves the part in the machine and then leaves that area so that the machine can be started Often the robot and the machine communicate with one another to check such things as whether the machine is open This check is not included in the following example User s Guide 17 9 Material Handling Routine leave_machine MoveJ p3 vmax z50 gripper1 MoveL p4 v500 z10 gripper1 MoveL p5 v100 fine gripper release_part MoveL p4 v200 z30 gripper1 MoveL p3 v500 z50 gripper1 2 7 Updating operating statistics Program Examples Comments Go quickly to position outside machine Go in to machine Go to release position Release part Go to position above part Go to position outside machine The number of parts produced during the day is written on the teach pendant display Routine update_cycle regl regl 1 TPErase TPWrite TPWrite TPWrite No of produced parts Num reg1 Comments Increment produced parts Clear the display A few blank lines The number of parts 2 8 Stopping
373. o confirm 7 9 Defining external torque When external equipment for instance a cable or a coiled hose affects any joint significantly the external torque should be defined using the following formula T A k 8 8 T external torque Nm A constant torque Nm k scale factor for position dependent torque Nm rad 8 joint position when position dependent torque is zero rad The formula is also illustrated in the figure below User s Guide 12 59 System Parameters T A a zero angle joint position Figure 29 External torque Example A coiled hose is mounted and affects joint 6 as follows e 0 Nm at 0 degrees e 5 Nm at 200 degrees 5 This external torque can be defined using A 0 6 0 k 500 x7 180 If the estimated value of a significant external torque is too low there could be unnecessary path deviations and the manipulator could be damaged If the estimated value is too high the performance of the manipulator will be reduced due to restrictive acceleration limits e Choose Topics Manipulator e Choose Types Arm e Select the desired arm and press Enter e Select the desired parameter and change its value e Press OK to confirm Parameter Description Ext const torque External constant torque Nm Ext prop torque Scale factor for position dependent torque Nm rad Ext torque zero angle Joint position when position dependent torque is zero r
374. obj in the field Wobj and then jog ging the robot e When programming it is important to have the work object in this case wobj1 pro grammed as an argument in each move instruction This will be automatically added to the move instruction if the work object is activated in the jogging window before starting the programming 8 3 Creating a new work object A work object should normally be placed in the system module User In this way it will be common to all programs which means that if a work object is modified all programs will also automatically be modified The work object can also be used for jogging when there is no program in the program memory e Open the Program Data Types window by choosing View Data Types e Select the type wobjdata and press Enter e Create the new work object using one of the following alternatives alt 1 Press the function key New The user and object coordinate systems will then coincide with the world coordinate system alt 2 Select an existing work object and press the function key Dupl The coordinate systems will then be the same as those duplicated A window appears displaying the name of the data e If you want to change the name press Enter and specify a new name e Press the function key Decl A dialog box appears displaying the basic wobjdata declaration User s Guide Calibration e If you want to save the data in another module s
375. object in this case turntable programmed as an argument in each move instruction This will be auto matically added to the move instruction if the work object is activated in the jogging window before starting the programming 10 16 User s Guide Calibration 6 2 Defining the User Frame for a rotational axis single This method will define the location of the user coordinate system of a rotational single axis type mechanical unit relative to the world coordinate system This user coordinate system should be used when a coordinated work object is used The definition of a user frame for a rotational external axis requires that the turntable on the external axis has a marked reference point The calibration procedure consists of a number of positionings for the robot s TCP on the reference point when the turn table is rotated to different angles See Figure 10 Axis of rotation as Turntable run by single external axis Position 2 F X Position 1 1 sagt Reference point on turntable Position 3 Position 4 Origin for user coordinate system of rotational single World X Figure 10 Definition points for a rotational axis The user coordinate system for the rotational axis has its origin in the centre of the turn table The z direction coincides with the axis of rotation and the x axis goes through the reference point Figure 11 shows the user coordinate system for two different posi
376. obot will be delayed and the performance of weldguide and conveyor will be decreased Brake on time Brake on time will define the time from when the robot stops to activation of the mechanical brakes This time should be kept high to maintain the reliability of the servo at high level User s Guide 12 83 System Parameters 12 84 7 23 CPU Optimization In some demanding applications CPU load problems may occur causing errors such as 50082 Deceleration too long or 50024 Corner path failure The parameters described below can be used to reduce these problems Path resolution Path resolution corresponds in some sense to the distance between two points in the path Increasing Path resolution means increasing that distance which leads to a decrease in the resolution of the path Increasing Path resolution is a way to deal with robot installations that have external axes with long deceleration times In such applications the warning 50082 Deceleration too long will be reported simultaneously generating a quick stop The path resolution parameter will then need to be increased until the problem disappears The need for tuning the path resolution parameter will increase when The acceleration value of an external axis and the robot is decreased Acc Set first parameter The acceleration derivative is decreased Acc Set second parameter The speed is increased The distances between closely program
377. odules Choose or create new modules 1 3 Creating a new program e Choose File New If the robot is already loaded with a program which has not been saved a dialog box appears and you will be asked whether you want to save it or not Then choose File New again e Specify the new name of the program in the dialog box that appears See Chapter 5 Starting up Entering text using the teach pendant in this manual for how to handle the text editor e Choose OK to confirm A program with only one empty main routine is created User s Guide Programming and Testing 1 4 Loading an existing program e Choose File Open A dialog box appears displaying all programs in the current directory see Figure 2 S Open Select a Program or a Module Mass memory unit Massmemory unit flp1 _ ROBOT1 lt 4 5 Current directory _ Go up 1 level WELD1 Program WELD2 Program USER1 System Module TEST Directory Unit Cancel OK Figure 2 The dialog box used to read programs e If necessary change the mass memory unit by pressing Unit until the correct unit is displayed e Select the desired program Move up or down in the directory by using either up or the desired directory down and press Enter lt e Choose OK to confirm When a program is already loaded into the system but has not been saved and you wish to open another program a dialog box app
378. of a work object it will only be necessary to jog to one position see Figure 6 pl 100 mm p2 50 mm p4 p3 MoveL pl MoveL pl MoveL p2 MoveL Offs p1 100 0 0 MoveL p3 MoveL Offs p1 100 50 0 MoveL p4 MoveL Offs p1 0 50 0 MoveL pl MoveL pl Figure 6 Two different ways of programming a movement Starting point Displacement in x direction Displacement in y direction Displacement in z direction MoveL Offs p1 100 50 0 v100 9 6 User s Guide The programming language RAPID e Program a positioning instruction as described in Programming a Position on page 3 e Select the position argument and press Enter lt e Press Func e Select the function Offs and press Enter A dialog box appears in which you can enter the arguments of the function See Figure 7 Function Argument Offs lt gt lt gt lt gt Point 1 1 New pl Next Func More Cancel OK Figure 7 The dialog box used to set an offset e Select the starting point e Press Next e Enter the offset the offset value in the x direction using the numeric keyboard e Press Next e Enter the offset in the y direction using the numeric keyboard e Press Next e Enter the offset in the z direction using the numeric keyboard e Press OK 2 Changing the Value of an Output An o
379. ogging Motion Supervision Turn Motion Supervision ON OFF Note Only applies to jogging Motion Supervision State On ON OFF Cancel OK Figure 5 The dialog box for motion supervision If you want to turn the motion supervision off or on e Press the function key OFF or ON e Press OK to confirm 2 Jogging the Robot 2 1 Jogging the robot along one of the base coordinate axes fe gt A l to jog the robot in a straight line e Set the keys uF e Select the field Coord see Figure 6 e Press the function key Base 4 9mm a yO Z 12 8 mm Q1 0 7071 Coord Base Q2 0 0000 Tool tool0 Q3 0 0000 Wobj wob3j0 Q4 0 7071 Joystick lock None xz y Incremental No 5 gt World Base Tool Wobj Figure 6 Specify the coordinate system in the Jogging window The robot will move the TCP along the base coordinate axes see Figure 7 6 6 User s Guide Jogging X Figure 7 Linear movement in the base coordinate system 2 2 Jogging the robot in the direction of the tool A e Set the keys to jog the robot in a straight line uF SF A e Select the field Coord see Figure 8 e Press the function key Tool Z 12 8 mm Ql 0 7071 Coord Tool Q2 0 0000 Tool tool0 Q3 0 0000 Wobj wob3j0 Q4 0 7071 Joysti
380. oint Point 1 e Point out the reference point on the turntable with the robot s TCP e Modify the position by pressing the function key ModPos e Rotate the second axis to a greater angle and repeat the above for the points Point 2 to Point n e Press OK to calculate the frame of the second axis To confirm cancel the new axis definition When OK is pressed after the points have been modified for an axis a dialog like the one in Figure 22 will appear Mechanical Unit Axes Calc Result Unit MHA160B1 Axis 1 Calculation Lo eiria g 1 10 Method n points n 4 Mean error 0 57 Max error 0 98 Cartesian X 7 08 Cartesian Y 35 55 Cartesian Z 97 00 File Cancel OK Figure 22 The result of the first axis definition The calculation log shows the calculated frame expressed in the world coordinate system 10 26 User s Guide Calibration Field Description Unit The name of the mechanical unit for which the definition of the axis is to be done Axis The chosen axis List contents Description Method Displays the selected method Mean error The accuracy of the robot positioning relative to the reference point Max error The maximum error for one positioning Cartesian X The x coordinate for the frame Cartesian Y The y coordinate for the frame Cartesian Z The z coordinate for the frame Quaternion 1 4 Orientation components for the frame The calculation result can be
381. ol0 fine tool0 File Edit Program Test Speed Running Program pointer PP Z P J gt MoveL v300 MoveL v300 MoveL v300 MoveL v300 Start FWD BWD Modpos Instr gt Figure 36 The Program Test window Function keys displayed Start continuous running of the program FWD one instruction forward BWD one instruction backward Instr gt select the Program instruction window again The program point PP indicates the instruction with which the program will start when you press one of the options Start FWD or BWD 3 Select the upper part of the window by pressing the List key 4 Reduce the velocity to 75 by pressing the function key see Figure 37 Correction is carried out in increments of 5 File Edit View Sp ecial Program Test EXERCISE main Speed 15 Running Continuous 1 4 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 amp 25 100 Figure 37 Correction of velocity 4 32 User s Guide Basic Operation Starting the Program 5 Move using the same key as in point 3 the cursor back to the first line of the program see Figure 38 File Edit View Special Program Test EXERCISE main Speed 75 Running Continuous 1 4
382. ol_z in meters Accepted position error in itera tive inverse kinematics procedure rot_tol_x rot_tol_y rot_tol_z in radians Accepted orientation error in itera tive inverse kinematics procedure base_pose_rot_u0 base_pose_rot_ul base_pose_rot_u2 base_pose_rot_u3 Rotation between user defined robot base and internal base according to Denavit Hartenberg definition no_of_joints 6 type GEN_KINO For robot with no wrist axes type GEN_KIN1 For robot with one wrist axis type GEN_KIN2 For robot with two wrist axes e Under ARM e For each arm of the robot in question rotating_move if rotating axes excluded otherwise e Under ARM_TYPE e For each arm of the robot in question length a according to Craigh s definition offset_x 0 offset_y 0 theta_home_position theta according to Craigh s definition offset_z d according to Craigh s definition attitude alpha according to Craigh s definition Structures with less than 6 axes require a LOCKED definition for all references to the inactive axes EXTERNAL ROBOT The following data needs to be defined e Under ROBOT_TYPE base_pose_rot_u0 base_pose_rot_ul base_pose_rot_u2 base_pose_rot_u3 Rotation between user defined robot base and internal base according to Denavit Hartenberg definition no_of_joints highest joint number type GEN_KIN e Under ARM e For each arm of the external robot in question User s Guide S
383. ommand File Add new parameters Read in the file that corresponds to the current installation one file for each axis used Rules for connecting external axes to the system for general information see Product Manual Installation and Commissioning External axes A maximum of 6 external axes may be connected to the system Measuring system connections One extra Serial Measuring board can be connected to measuring system 1 On this one axis can be physically connected to node 4 on the board Up to four SMBs can be connected to measuring system 2 The measurement boards must be numbered in consecutive order starting with board_1_m2 followed by board_2_m2 etc Each axis in the measurement system must have its own unique node number The axes can be connected to the measuring boards in an arbitrary way Drive system connections Max one external axis may be activated in drive system 1 If drive system 1 2 is used drive system 2 must not be used Only one configuration file per axis number may be read in 12 64 User s Guide System Parameters Configuration files with standard data on Control Parameters Configuration file Logical axis Measuring system Drive system System Node System Unit position Node MN4M1D1 7 1 4 7 1 0 2 MN4M1D2 T 1 4 7 2 1 2 MN4M1D12 7 2 4 7 2 0 2 MN1M2D1 8 2 1 1 0 2 MNIM
384. on the second axis second axis ey ee a IL PB Turntable first axis Figure 17 Geometric structure of an orbit station The definition of the user frame requires that the turntable has a marked reference point The origin of the user frame is located in the centre of the turntable with the z axis coinciding with the second axis of rotation The x axis goes through the reference point see Figure 18 Y AZ Reference point ES X X a a b Figure 18 The turntable seen from above a and side b The user frame is determined by two definition procedures One procedure for the first axis and another similar procedure for the second axis These two procedures are per formed separately but both are necessary to complete the user frame definition e Press the Miscellaneous key and select the Service window e Choose View Two Axes Definition A dialog containing all synchronized mechanical units is shown e Select the mechanical unit and press Enter or Def User s Guide 10 23 Calibration A dialog like the one in Figure 19 will appear po Mechanical Unit Axes Definition Unit MHA160B1 Method n points n 4 Axis eee Point Status 1 4 Point 1 Modified Point 2 Point 3 Point 4 ModPos Cancel OK Figure 19 Dialog for definition of axes Defining the first axis Before defining the first axis both axes must be run to their calibration positi
385. on the slave unit 71148 No access to dsqce344 DescriptionReason Access to the dsqc344 is denied due to d Check 1 The dsqc344 is faulty Replace board 2 Check dsqc344 internal confiuration 71149 IBS command failure DescriptionReason Incompatible definition due to d Check 1 Check the I O system parameters 2 Restart the system 16 99 System and Error Messages 71150 The dsqc344 is busy DescriptionReason The response service capability is limited due to IBS configuration Check 1 Check dsqc344 internal confiuration 2 Change cycle time on the slave unit 71152 InterBus S bus failure DescriptionReason s bus failure Lost contact at address d d Check 1 Check InterBus S bus at the above address 2 Restart the system 71153 Can t access parameter DescriptionReason Unit s has parameters that can t be edited from the teach pendant Check 1 Save the EIO configuration to a file 2 Use a text editor to change the parameters 71154 The unit has no power DescriptionReason Unit s has no power connected Check 1 Attach power to the unit 71155 The unit is faulty DescriptionReason Unit s has not been correctly connected Check 1 Diagnose with CMD application 2 Modify the dsqc344 loacal start up procedure 3 Replace the dsqc344 firmware 16 100 71156 IPC queue full DescriptionReason The ipc queue s was full when sending to trap routine Check
386. ons The procedure to define the first axis consists of a number of positionings for the robot s TCP on the reference point when the first axis is rotated to different angles Position 1 is the position of the reference point when both axes are fixed to their calibration posi tions The following positions position 2 3 4 etc are the positions of the reference point when the first axis is rotated to greater angles in successive steps See Figure 20 N Position 4 y Position 3 Turntable l Second axis in calibration position World X Figure 20 Definition of the first axis Four positionings of the robot s TCP on the reference point are performed with the first axis rotated to different angles 10 24 User s Guide Calibration Defining the second axis Before defining the second axis both axes must be run to their calibration positions The procedure to define the second axis consists of a number of positionings for the robot s TCP on the reference point when the second axis is rotated to different angles Position 1 is the position of the reference point when both axes are fixed to their cali bration positions The following positions position 2 3 4 etc are the positions of the reference point when the second axis is rotated to greater angles in successive steps See Figure 21 Position 1 X2 Reference point Position 4 Second axis ie Y World x Figure 21 Definition of the second a
387. ons of the selected routine view the error handler of the selected routine view the backward handler of the selected routine view only the routines in the current module see page 8 57 view all routines in all modules see page 8 57 add remove an error handler to the selected routine see page 8 53 add remove a backward handler to the selected routine see RAPID Reference Manual Programming off line Used to mirror a routine or a module see page 8 39 User s Guide Quick Reference 3 5 Window Program Data Data type Data Create new data The Program Window File Edit View Data Special Program Data WELDPIPE tooldata In Module Name 3 3 gripper gunl gun2 New Decl Dupl Types gt Test gt Duplicate Go to the window Program Test Change the declaration View all data types 3 5 1 Menu Data Data 1 2 Value Types U AUW In Module In System In Routine routine name New Array Command Value Types In Module In System In Routine New Array User s Guide Used to read or change the current value of selected data see page 8 50 call up the list with all data types see page 8 45 call up only the data in the current module see page 8 58 create new data see page 8 47 call up all routine data declare a new array data 18 13 The Program Window Quick Reference 3 5 2 Menu
388. ontrol time delay Time delay s that starts when the speed lt Control speed limit and before the regulator should be turned off Control speed limit Speed as a of max speed at which the time delay starts When more that one brake relay is used read in a new relay file file RELAY and User s Guide 12 69 System Parameters 12 70 repeat the procedure above e Restart using File Restart Tuning the axes The servo control method can be adjusted to achieve the best possible performance e For an uncalibrated axis choose Types Uncal control master 0 and specify the tuning values for Kp Kv and Ti that give good performance See below under the description for Lag control master 0 for an explanation of these parameters e For a calibrated axis choose Types Lag control master 0 and specify the values that give good performance Parameter Feedforward mode Delay Bandwidth Df Dw Inertia Kp gain pos loop Ky gain speed loop Description Possible options are No Spd or Trq Each one corresponds to a different mode of the controller as described below No This is the simplest configuration The controller is driven by the position error lag Because a relatively large lag is needed to move the axis the position error can be large Spd In this configuration the controller receives information about the desired speed of the axis As a result the position lag is greatly reduced compared to the
389. oordinate system Obj The origin of the object coordinate system The calculation result can be saved in a separate file for later use in a PC Note however that this file cannot be read by the robot e Press the function key File User s Guide 10 39 Calibration 10 40 e Specify a name and a place to save the result e Choose OK to confirm the save The definition is now complete press OK to confirm the new work object but before proceeding with other tasks verify it by jogging linearly in the work object s coordinate system If the work object was stored in a system module save this module 8 7 Defining a moveable object frame Method 1 e Use the method for defining a work object See Using the robot to change the work object on page 38 When using this method please observe that the coordination flag i e the component ufprog in the work object data must be temporarily set to TRUE You must point out three positions for the user system which must be placed as the coordinated one and three positions for the object system If the user system is not possible to reach use method 2 or 3 below Method 2 e Activate the coordinated work object and jog the robot to the point where you want to place the origin of the object frame e Read the coordinates x y z for this position in the jogging window e Write these values in the o_frame component of the work object data This will shift the object frame to the
390. oose Topics Controller 5 1 Activate delayed safeguarded space stop A delayed stop gives a smooth stop The robot stops in the same way as a normal program stop with no deviation from the programmed path After approx 1 second the power supplied to the motors shuts off The stopping distance can be longer than at a hard stop e g emergency stop e Choose Types SafetyRunChain e Select the safety function to be changed and press Enter or add a new one by pressing Add e Define the function and whether or not it shall be active True SoftAS Delayed automatic mode safeguarded space stop SoftGS Delayed general mode safe guarded space stop Press OK to confirm 5 2 Activate Hold To Run Control When using the Hold To Run control the program start key must be held down all the time in order to execute a program This function is always activated in the manual operating mode at full speed but can also be activated at reduced speed e Choose Types SafetyOpKey e Select the safety function to be changed and press Enter or add a new one by pressing Add e Define the function and whether or not it shall be active True Press OK to confirm User s Guide 12 37 System Parameters 5 3 Defining event routines Special system events such as program stop can be connected together with an ordi nary routine When the event occurs the corresponding routine is executed automati
391. or Note If the program pointer is moved into a FOR statement the program will run the rest of the FOR statement to the end and then continue with the next statement To start the program from the beginning e Choose Special Move PP to Main The program pointer and the cursor are set to the first instruction in the main routine To start the program from a routine The program pointer and cursor can be moved to any routine procedure with no parameters If it is moved the call hierarchy at that time will no longer be valid which means that program execution continues from the start of the routine after the routine has been fully executed e Choose Special Move PP to Routine A dialog box appears displaying all possible routines e Select the desired routine and press OK To execute a routine without losing the call hierarchy A routine without parameters can be executed without losing the call hierarchy and program settings e g program displacement mechanical unit activation etc e Choose Special Call Routine A dialog box appears displaying all possible routines e Select the desired routine and press OK User s Guide Programming and Testing When the program pointer reaches the end of a called routine you are asked whether to run the routine again or to return to the original program pointer where the Call Routine was performed To execute a service routine without losing the call hierarchy A preconfigure
392. or Task 16s No more interrupt number available Check There is a limited number of interrupt numbers available Rewrite the program to use fewer interrupt numbers This message may also occur as a consequence of a system error 40201 Value error Task 16s Negative operand i not allowed Check The MOD operator only allows non negative operands Change the program to make sure that the operator is not applied to negative values 40202 Type error Task 16s Dimensions i and i of conformant array dimension number i are incompatible Check The array is not of the expected size Array assignment may only be performed on arrays of identical size 40203 Reference error Task 16s Optional parameter 16s not present Check The value of a non present optional parameter may not be referred Use the predefined function Present to check the presence of the parameter before using its value 40204 Value error Task 16s Array index 1 for dimension number i out of bounds 1 1 Check The array index value is non positive or violates the declared size of the array User s Guide Base Ware OS 3 1 40205 Value error Task 16s String too long Check String value exceeds the maximum allowed length Rewrite the program to use strings of lesser length 40221 Execution error Task 16s Execution aborted Check Execution was aborted due to a fatal error 40222 Limit er
393. or Arcitec power source is not responding Check Check connection to power source 16 109 System and Error Messages 117506 Communication error Messages from Arcitec power source are not possible to evaluate Messages are too short Check Check connection to power source Check Arcitec configuration file 118000 Ext CAN com failure Too many requests without response Check Check communication configuration 118500 Arcitec tuning error There are no Arcitec system defined Check Define Arcitec system or do not write towards Power Source 118501 Arcitec tuning error Parameter does not exist Check Change parameter identity 118502 Arcitec tuning error Parameter must be numerical Check Change parameter identity 118503 Arcitec tuning error Parameter value outside limits Check Change parameter value 119000 Installation error External axes are not allowed in this type of robot configuration Check Remove mechanical units 9 Spotweld error messages 120001 Spot weld system error Spot weld proc not idle Check Set the process state defined by SwInit to idle 120002 Spot weld system error Parameter s 16 110 120003 SwStart Timeout negative 120004 SwInit Interrupt negative 120005 Procld The reason is either Procld does not correspond to the value given from SwInit The spot weld process has been cancelled 120006 Spot weld comm error Reason s 120007 Response
394. or Messages 10083 RAPID Task supervision Task s is not running the system will be set in motors off state Ps Check See previous messages for the cause 10084 RAPID Task supervision Task s is not running the main task will also stop Ps Check See previous messages for the cause 2 System error messages 20010 Em stop state active Em stop reset is required Press the panel button 20011 Em stop state active Em stop reset is required First release the Em stop button and then press the panel button 20012 Sys failure state active Fatal non recoverable system error Warm start is required Check Switch the mains switch off and on again if the soft restart command is ignored or not possible to reach 20024 Enable chain timeout Two channel status timeout Check The acknowledgement for a two channel enable chain status change was not received within the expected time 20030 Axis not commutated One or several internal drive unit axes are not commutated 20031 Axis not calibrated One or several absolute relative measurement axes are not calibrated 16 27 System and Error Messages 20032 Rev counter not updated One or several absolute measurement axes are not synchronized Check Move the robot to the sync position and update the revolution counters 20033 Axis not synchronized One or several relative measurement axes are not synchronized Check Order Motors On and synchronize
395. or messages please check line voltage for one phase missing 20208 Chain switches open One or many switches in chain open 20209 External Contactor open 20210 Motor Contactor open 20211 Two channel fault Enable from backplane was not allowed to be closed Runchain two channel fault has not been reset Check First open both channels and then close them again to reset runchain Please check the safety guard that caused the status conflict 20212 Two channel fault Runchain was not allowed to be closed Runchain two channel fault has not been reset Check First open both channels and then close them again to reset runchain Please check the safety guard that caused the status conflict 20213 Two channel fault Runchain two channel fault has not been reset Check First open both channels and then close them again to reset runchain Please check the safety guard that caused the status conflict 16 32 20221 Chain conflict Status conflict for one or many switches in chain Check Please check the two channel safety guard that caused the status conflict 20222 Limit Switch conflict Status conflict for the Limit Switch chain Check Please check the two channel safety guard that caused the status conflict 20223 Emergency Stop conflict Status conflict for the Emergency Stop chain Check Please check the two channel safety guard that caused the status conflict 20224 Enabling
396. ore information of C Start and I Start see Product Manual Installation and Commissioning User s Guide 14 11 Service 14 12 User s Guide Screen Viewer CONTENTS Page TD WSO SCHOO i EEO ASEE EA A E ETE EE A EAEE ETE 2 The ScreenViewer Window seeeseoesooccsscssooesocescocesoecssocesocesoosscocessecesocesooesooesssessseeesoeee 3 The SCC CIAO PUNO TAS cscs caves ckoncedaawes Gane cosavenvaatvavasedvescevenonreducnes coneceeascaeducuncnaaseunebcanseciaee 4 The Screen LO ain aig seccssseceiisess sevcesscsancsvaevecacessunouasoncsevaswas Sor EESE EE EEEE E artan 5 The Screen nfOrimatioin cc ccccsisesscccvesscccsd scscacssdesccescdcccscdedesescacteddscadtecedessdescecsedeveccacs etcesess DH nan A UU 6 The Screen Dis plea yes eis csp in cassewes dese a vaceyaGei vacay cues easy cave cuba ex aeen ca dacava geen eenao we ossessi User s Guide 15 13 Screen Viewer 15 14 User s Guide Screen Viewer Screen Viewer Srceen Viewer is used to display user screen packages installed load a user screen package remove an installed user screen package list the user screen packages installed display information on the user screen packages installed 11 User screen The user screen is a screen composed of text or lines function keys pop up menus and input fields defined by the ScreenMaker PC tool These user screens can be grouped in a user screen package file under a specific name Ex SpotTime
397. ored The mirrored routine will be given this name If the Enter key is pressed when this field is selected a text input dialog will be displayed The work object to be used when applying the mirror function on robtarget variables If the Enter key is pressed the work object selection dialogue will be displayed The frame to be used as the mirror plane The frame is of the type wobjdata If the Enter is pressed a mirror frame selection dialogue will be displayed Specifies the mirroring of orientation When this field is selected the function key bar shows the alternatives X and Y The mirroring of orientation is then selected by pressing the corresponding function key User s Guide Programming and Testing 10 Creating Data 10 1 What is data Data is used to store values that can be used at a later stage in the program Data is grouped into different data types that describe its contents and its field of application Data type Used for num Numeric values registers counters bool Logical values true or false robtarget Position data tooldata Tool data see Chapter 10 Calibration wobjdata Work objects see Chapter 10 Calibration pose Program displacement frames see Chapter 10 Calibration For more detailed information on data and its contents see the appropriate data type in RAPID Reference Manual Data Types Data must be defined declared before
398. orient_jog_m and joint_m File ROBOT_E CFG is intended for the external manipulator Loading this file will define the parameter instance name string joint_e When more than one external manipulator is used each external robot file should have its unique name e g ROBOT_E1 CFG ROBOT_E2 CFG Also the JOG_JOINT names in each file should be changed from joint_e to joint_el joint_e2 respectively User s Guide System Parameters If joystick directions for several mechanical units are to be defined the template files for all the units can be loaded here When the file is loaded perform a Restart e Choose Topics Manipulator e Choose Types 1 Robot e Select robot unit e Press Enter e Select the desired parameters Linear jog dir Reorient jog dir Joint jog dir to be changed Selecting the default type restores factory default jog directions Do not perform the Restart requested here e Repeat for all robots e Press OK to confirm e Choose Types 2 For each selected parameter type above e Select the desired parameter type e Edit the elements e Press OK to confirm e Perform a Restart to activate the modifications to the joystick directions When joystick directions for both robots and single axes are to be modified it is not necessary to perform the restart until all the modifications have been made Linear jogging e For each coordinate system specify the desired axis direct
399. osdrr esot s ssas sdr tss r vkb sss isr ESSEE Esses askie iss 37 5 1 Activate delayed safeguarded space stop ssssssssssssssesssssessseessressessseresseessseesssesse 37 5 2 Activate Hold To Run Comics o 3 ssececsachestonstasaasveacnas seacaedaecaeial saecadasaiqeeusienecaane 37 5 3 Defining event routines seinan n a aso i ara iiae eias 38 5 4 SCOUT VANS regain distances soren ier a a a a a 39 5 3 System MISCELLANEOUS esa a A n ios suas Nuataamndbesee tenaumnedaves 40 5 6 Automatic loading of modules and programSs sssssssssessessseeeseressseesseesseesseessees 41 5 7 Defining multitaskihg sonicne innesi a aE K a EER 42 6 Topic TeachPendant sssssssosssiscssssisscsosssissosssssssssvsssssssoseessssssssssossssssssissssssssssee ssssss s ss 45 6 1 Defining Optional Packages secsisiyeis intest ape ee i ti a Ea eei 45 User s Guide 12 1 System Parameters Page 6 2 Defining Pile Extension siisiiisssacissnczeeasaessaisisageatoaapavaavaioosaeeassnezs vabsevedeadpovaccesnseeurs 45 6 3 Defining authorisation and Confirmation ces ceeeesseeeseceseceeeeeeseecnaeeeeesseeeenees 46 6 4 Activation of Limited ModPos Function eee eesecesceseeeseecssecseeeseneeeaeeesaeenes 49 G3 PEOSTAMIM AOE KEYS 3 Sees ieo SS psa Seay ac os onsen a o lease eases 50 6 6 Defining Running Mode Settings 0 0 0 eee ceesseceenecesececeeneeceeeeeceeeeecneeeeeneeeeeeeeeees 51 7 Topic TVLEIUPULLERLO Gs oy guies icsncevccasa ccesec so gataccbv gov tise
400. osition data is changed immediately after each step but will not affect the robot path until the next instruction using this position data is executed The values in the Present column will be used in this instruction The total tuning will be displayed in the Tuning column Note Ifanamed position data is modified all instructions which refer to that position data will be affected Unnamed positions marked as in the instruction cannot be tuned See also Chapter 8 Programming and Testing Tuning position during program execution The tuning function can be disabled in automatic mode See chapter 12 System Parameters Topic Teach Pendant 8 Operator Dialogs Special instructions can be created in the program and used as a form of communication between the program and the operator see Figure 9 Operator Operator Log The robot is now picking up a part from the front conveyor belt Number of parts to be processed 25 Figure 9 Example of a message sent to the operator e You can return to the Production window by pressing ggg and choosing Production Sometimes the operator must respond before program execution can continue see the example in Figure 10 User s Guide 11 9 Production Running Program Waiting for data How many parts to be processed OK Figure 10 Use the numeric keyboard to answer questions from the program e Use the numeric keys wh
401. ot controller can send a message at start up This variable is used for setting up subscriptions of RAPID events User s Guide System Parameters NFS Remote Mounted Disk Additionally the following parameters must be set if the Type is set to NFS Server Address Trusted Local Path Server Path User ID Group ID The IP Address of the computer with the NFS server This flag decides if this computer should be trusted i e if los ing the connection should make the program stop YES NO The name of the unit on the robot If for example the unit is named pc the name of the fest prg on this unit would be pce test prg The name of the exported disk on the remote computer The UNIX user id for the mounting This parameter must be the same for all mountings on a robot The UNIX group id for the mounting This parameter must be the same for all mountings on a robot Show on Teach Pendant User s Guide This flag decides if the unit should be visible in the list of units on the teach pendant YES NO 12 35 System Parameters 12 36 User s Guide System Parameters 5 Topic Controller The following parameters are found under the Controller topic Activation of delayed soft safeguarded space stop Activation of Hold To Run Control Event routines Maximum regain distances System miscellaneous Automatic loading of modules and programs Tasks option Multitasking is required e Ch
402. ould be included from the beginning because it is a little tricky to add it afterwards A program displacement however which is acti vated in a separate instruction is very easy to add afterwards User s Guide 10 35 Calibration 10 36 8 2 Using work objects In the checklist below the steps required to define and use a work object are described In each step there may be a reference to another chapter in this manual where more details of the specific actions to be taken will be found e Before starting to program the work objects to be used must be defined First create a new work object and give it a name e g wobj1 see Creating a new work object on page 36 e Define the work object by using the robot to point out three points on the user frame and the object frame respectively See Using the robot to change the work object on page 38 Please note that if the same positions are used both for the user frame and for the object frame then all the locations will go into the user frame and the object frame will still be zero It should also be noted that it is possible to update the values of the work object manually See Manually updating the user and object coordinate system of the work object on page 37 e Now check that the definition of the work object is correct by jogging the robot in the object coordinate system This may be done by choosing the Wobj in the field Coord in the jogging window and the work object e g w
403. outine is created Routine Definition In USER Name routinel Decl Cancel OK Figure 7 A new routine is created e Change the name by pressing Enter and specify a new name If you want a normal subroutine procedure without parameters you should finish here by pressing OK In other cases the characteristics of the routine must be defined e Press the function key Decl e Change the characteristics of the routine by selecting the appropriate field then Press Enter and specify the desired alternative in the dialog box that appears on the display fields marked with Choose an alternative using the function keys fields marked with E Field Description Name The name of the routine a maximum of 16 characters Type Specifies whether the routine is to be a procedure Proc a function Func or a trap routine Trap In Module The module in which the new routine will be used Data type The return value for the data type only specified for functions If the routine is not to include any parameters you can terminate the definition by pressing OK In other cases the parameters must also be defined e Select the parameter list by pressing the List t key e Add a parameter by pressing the New function key User s Guide Programming and Testing New parameters are placed after the selected parameter in the list
404. oveL v tool0 7 Change Selected WaitTime A 8 Value MoveL v300 fine tool0 9 ModPos 0 Search Show Hide IPL Figure 58 The Edit pull down menu Press the Edit menu key again to remove the menu See the User s Guide for more detailed information 4 50 User s Guide Basic Operation Storing the Program on Diskette 14 Storing the Program on Diskette You are now going to copy the program to a diskette Use 3 5 HD High Density DOS formatted diskettes Do not use the Setup diskette to store the exercise program 14 1 Storing on diskette 1 Choose the Program Instr application see Figure 59 if you are not already in it 5 Figure 59 The Program window appears on the display 2 Press the File menu key The window in Figure 60 appears 1 Open 2 New 3 Save Program 4 Save Program As S PELNE 6 Preferences File Edit View IPL1 IPL2 EXERCISE main 1 6 ZA Coolt z10 tool0 fine tool0 fine tool0 veL v300 fine tool0d 7 Check Program 8 Close Program Copy Paste OptArg ModPos Test gt Figure 60 Commands in the File menu 3 Select File Save Program as and press Enter You could alternatively use the numeric keyboard to enter the number shown in front of the function name The dialog box in Figure 61 appears on the display User s Guide 4 51 Storing the Program on D
405. ower up Checksum error Check Probably caused by low memory backup battery voltage Welding equipment will be reset to a default state Data in Welddata Unit will be lost Possible to run without limitations 117020 Welding equipment error Non volatile RAM data value failure detected in Welddata Unit at power up Non numeric setting parameter out of range Check Welding equipment will be reset to a default state Data in Welddata Unit will be lost Possible to run without limitations 117021 Welding equipment error Invalid combination of non numeric setting parameters in Welddata Unit detected at power up Check Welding equipment will be reset to a default state Data in Welddata Unit will be lost Reset welding equipment with power switch 16 106 117022 Welding equipment error CAN bus external transmit buffer overflow in Welddata Unit Check Welddata Unit are unable to transmit data at the needed rate Could be caused by unnormal occupation on the bus Reset welding equipment with power switch 117023 Welding equipment error CAN bus external receive buffer overflow in Welddata Unit Check Welddata Unit are unable to process received messages at the needed rate Reset welding equipment with power switch 117024 Welding equipment error Fragments not in number order when Welddata Unit received a fragmented message Check The parts of a fragmented message were not received in proper ord
406. pl DEMO 1 1 Go up one level Unit New Dir Cancel OK Figure 63 The Save Program as window 7 Press OK A window like the one in Figure 64 appears Save Program as Name XXXXX Mag Disk Changed DH The contents of the disk has been changed since last read per Reread the contents Storing the Program on Diskette Reread Cancel Unit New Dir Cancel OK Figure 64 An alert box 8 Press Enter The window in Save Program as Massmemory Unit flpl Name XXXXX Figure 65 appears Empty volume Unit New Dir Cancel OK Figure 65 Window for storing the program on diskette 9 The program is saved onto diskette when you press OK see Figure 65 10 Close the dialog box User s Guide 4 53 Storing the Program on Diskette Basic Operation 4 54 User s Guide Basic Operation Printing Programs 15 Printing Programs 15 1 Using a PC It is also possible to print programs from a PC Almost all word processing programs can be used The only requirement is that the computer can handle DOS formatted dis kettes 1 Store the program on diskette 2 Enter the program into the PC 3 Print User s Guide 4 55 Printing Programs Basic Operation 4 56 User s Guide Basic Operation I O Signals 16 I O Signals This chapter describes how you can program an instruction which activates a digital outpu
407. ponent not allowed in definition of named record Check Complete the definition or change the data name to a place holder 40118 Not authorized Task 16s The function User defined data types is not installed in this system Check Install the option Developer Functions in the system 40119 Reference error Task 16s Cannot use the semi value type 16s for record components 40120 Reference error Task 16s Illegal reference to installed task object 16s from shared object Check Install the referred object shared or install the referring ReaL object archive or RAPID module in each task not shared 40141 Argument error Task 16s Argument for PERS parameter 16s is not persistent reference or is read only Check Make sure the argument is just a persistent or persistent parameter reference and it is writeable Do not use around the argument User s Guide Base Ware OS 3 1 40142 Argument error Task 16s Argument for VAR parameter 16s is not variable reference or is read only Check Make sure the argument is just a variable or variable parameter reference and it is writeable Do not use around the argument 40157 Instruction error Task 16s Interrupt number is not static variable reference is shared or is read only Check Make sure the interrupt number is just a variable or variable parameter reference The variable must be static and not shared The v
408. ppy Disk Error Internal error Overrun Check 1 Repeat attempt 2 Restart the system 31223 Floppy Disk Error Bad floppy or internal error Check 1 Repeat attempt 2 Change Disk 3 Restart the system User s Guide Base Ware OS 3 1 31224 Floppy Disk Error Floppy write protected Check 1 Remove write protection 31225 Floppy Disk Error Bad Floppy Address mark missing Check 1 Change Disk 31226 Floppy Disk Error Bad data on floppy Check 1 Change Disk 31227 Floppy Disk Error Bad floppy Missing cylinder Check 1 Change Disk 31228 Floppy Disk Error Bad floppy Bad cylinder Check 1 Change Disk 31229 Floppy Disk Error Bad floppy Bad address mark in data Check 1 Change Disk 31401 DMA error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board 31402 DMA error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board 31403 DMA error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board User s Guide BaseWare OS 3 1 System and Error Messages 31404 DMA error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board 31408 Axis computer error Check Replace robot computer board 31409 Robot computer error Check Replace robot computer board 31410 Axis computer error Check Replace robot computer board 31411 Axis computer error Check Replace robot compute
409. press Enter Parameter Description User s Guide 12 19 System Parameters 12 20 Unit Type Name of the unit type Vendor Name of the vendor that manufactures this unit type Product Description of this unit type Vendor ID Vendor s identification code Product ID Unit s product identification Device Type ID Unit type identification code Major Revision Major revision for the software resident in the unit Minor Revision Minor revision for the software resident in the unit Digital Inputs Maximum number of digital input signals available on this unit type Digital Outputs Maximum number of digital output signals available on this unit type Analog Inputs Maximum number of analog input signals available on this unit type Analog Outputs Maximum number of analog output signals available on this unit type Adding User Defined I O Unit Types Option T O devices that does not have a unit type equivalent listed on the teach pendent needs to be defined in the EIO CFG configuration file This cannot be done from the teach pendant It has to be done using a standard PC User defined unit types are defined in the unit type section of the configuration file Create this section by writing EIO_UNIT_TYPE at the end of the file The unit types are defined in the configuration file using the syntax below filling in the appropriate italic value the figures below are only examples EIO_UNIT_TYPE Name typename
410. production for the day If the operator presses Stop production and the robot has completed a work cycle the robot goes to home position In addition the production figures for the day the day s date followed by the number of parts produced are written on diskette Routine stop_production Comments MoveJ home v500 fine gripper1 Go to home position Open flp1 File logfile doc file Append Open the file for writing Write file CDate Num reg 1 Write to the file Close file Stop Close the file Stop program execution Before a file can be opened the data file must be created by the type iodev The real name of the file is logfile doc User s Guide CONTENTS 1 The Jogging Window eessoessoccssecssccesocesocessessoccesocesooesooeessessoee Lil Window JOS SINS nenien ii KL Went Special ineine aaetaer sees 2 The Inputs Outputs Window scccssccsssccssssccsssccssssscsssescess 2 1 Window Inputs Outputs eeeeceececseececeeeeeeeseeeesteeeenaes Dell Menu ET Gist sang cues e Jak eae eagle ters csnahane beads 212 Menu Edit xsicatsssa Get rere eataa sd DSM Men VAC Waasia R Ea 3 The Program Window eoesssoocsssosecesssocessooecesooceesosecesssoosessoossee 3 1 Moving between different parts of the program DD General MENUS ceini e R S eM Me AE E O 3 22 Ment Bit sca cc inaa n a 3 29 Menu NIE Weedon der a Saletan ET 3 3 Window Program Instr
411. protocols will be displayed as shown in Figure 15 12 32 User s Guide System Parameters File Edit Topics Types System Parameters Communication Transmission Protocols Name Type PhyChannel YP y 1 1 slipl SLIP siol com2 XON XOFF sio2 Add Figure 15 System parameters of the type Transmission protocol e Select the transmission protocol to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value Press OK to confirm Parameters Name Type PhyChannel SLIP Description Name of the transmission protocol max 16 characters The name must be unique and must not be used anywhere else Type of transmission protocol None XON XOFF SLIP TCP IP See Figure 13 Name of the physical channel the protocol should use Additionally the following parameters must be set if the Type is set to SLIP Local Address Remote Address TCP IP Local address of the SLIP connection Remote address of the SLIP connection Additionally the following parameters must be set if the Type is set to TCP IP Local Address Subnet Mask XON XOFF User s Guide Local IP address Note that the robot will use 4 IP addresses This address ta 1 2 3 e g 192 168 1 1 192 168 1 2 192 168 1 3 and 192 168 1 4 The subnet mask of the ethernet interface This protocol can only be used if ASCII v
412. r 1 00 These user screen packages are loaded removed and displayed via the ScreenViewer window For more detailed information on the user screen packages see the Product Specifica tion RobotWare 12 The ScreenViewer Window e Press the Miscellaneous key e Select Screen Viewer in the dialog box that appears e Press Enter v The Screen Viewer window comprises a number of different windows Window title Screen Options Screen Loading Screen Information Screen Display User s Guide Used to select from the three options below load a user screen package list the user screen packages installed display the user screen packages installed 15 15 Screen Viewer 13 The Screen Options The screen options window is always available if no user screen packages have been installed If at least one user screen package has been installed the screen options win dow will be available for one minute after the start up if the controller is in the manual mode never if the controller is in the automatic mode during the start up User Window Manager Automatic start in xx seconds Load Info Start Figure 7 The screen option window The choices available are Load to display the screen loading window Info to display the screen information window and also to remove packages Start to display the screen display window If the screen option win
413. r board 31414 Main computer error Check 1 Replace main computer board 2 Replace robot computer board 31415 Main computer error Check Replace main computer board 31418 DMA transfer error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board 31419 DMA transfer error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board 31420 DMA transfer error DMA transfer error in ROBOT COMPU TER Check Replace robot computer board 16 37 System and Error Messages 31501 Battery voltage too low Battery voltage too low on battery 1 Check Replace battery 1 31502 Battery voltage too low Battery voltage too low on battery 2 Check Replace battery 2 31503 Battery voltage too low Battery voltage too low on both batterys Check Replace batterys 31505 Battery cirquit error Check Replace robot computer board 31605 Memory error IO computer Check Replace robot computer board 31606 Memory error IO computer Check Replace robot computer board 31607 Memory error IO computer Check Replace robot computer board 32118 MC RESET ERROR Main computer running in spite of RESET command Check Replace main computer board 32247 Mailbox 1 interrupt error Mailbox 1 interrupt error on IO computer Check Replace robot computer board 16 38 32248 Mailbox 2 interrupt error Mailbox 2 interrupt error on IO computer Check Replace robot co
414. r is acceptable press OK to confirm the new user frame not acceptable redefine by pressing Cancel e Choose File Restart in the Service window to activate the user frame User s Guide 10 19 Calibration 10 20 The definition is now complete but before proceeding with other tasks verify it by jogging the mechanical unit in coordinated mode Note The user frame is stored in the system parameters as the base frame of the external mechanical unit The user frame in the corresponding work object is therefore not used 6 3 Defining the User Frame for a two axes mechanical unit Method 1 This method will define the location of the user coordinate system of an Orbit type mechanical unit relative to the world coordinate system This user coordinate system should be used when a coordinated work object is used It should be noted that this method requires that the kinematics relationship between two axes of the mechanical unit are defined in the robot system configuration There fore this method can only be used for workpiece manipulators supplied by ABB where a ready made configuration was included in the delivery For other types of workpiece manipulator see Defining the User Frame for a two axes mechanical unit Method 2 on page 23 The definition of this user coordinate system requires that the orbit turntable is marked with a coordinate system as shown in Figure 14 The coordinate system must have the x axis
415. ration i e they can function independently of the overlaying layers e Choose Topics Communication 4 1 Defining physical channels e Choose Topics Communication e Choose Types Physical Channels All defined physical channels will be displayed as shown in Figure 14 User s Guide 12 31 System Parameters File Edit Topics Types System Parameters Communication Physical Channels Name Type Channel ae 1 1 siol sio 1 Add Figure 14 System parameters of the type Serial Channels e Select the physical channel to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value Press OK to confirm Parameters Description Name Name of physical channel max 16 characters Type Type of physical channel SIO ETHERNET See Figure 13 SIO Serial Channels Additionally the following parameters must be set if the Type is set to SJO Channel Channel number 1 2 Baud rate Baud rate for the serial channel 300 19200 Parity Type of parity for serial channel Odd Even None No of bits Number of data bits 7 8 No of stops bits Number of stop bits 1 2 RTS CTS Control RTS CTS flow control when sending from the robot ON OFF RTS CTS is not available on channel 2 4 2 Defining Transmission Protocol e Choose Topics Communication e Choose Types Transmission Protocol All defined transmission
416. ration position of each axis 12 54 43 Defining Supervision OVel ove eis a Gays e r eee ees 12 54 7 4 Tuning the motion supervision cceeeecesceceeeeeceeceeceeeeeceeceecseeeeceteeeetaeers 12 55 J Defining teach mode Speed ti c sees ade ieee eaten andes Ss 12 56 7 6 Defining independent motion 2 0 ceeeseecesceceeeeeceeeeeceeeecseeeeseeeeeeereaees 12 56 Tl D fining arm load ctsatsaseatecectect lt astatetanctaseaseaseuateg E R ENE 12 57 7 8 Defining arm check point ssseesesssessseeesseeessessersseeessessseessresseesseeesseesssees 12 58 7 9 Defining external torgen eeen a i e heehee 12 59 7 10 Defining friction compensation sssessssssesssesesseetsstessetssersseresseeesseesseesse 12 60 7 11 Defining the base coordinate system sssessssssssssesessetesseessresseesseessseesssees 12 61 7 12 Defining external manipulators with more than one AXIS 0 0 0 ceeeeeeeeeeees 12 62 7 13 Defining a track motion with coordinated motion 0 0 0 eee eeeeeeeeeeneeeeeeee 12 63 7 14 Defining an external mechanical unit coordinated with the robot 12 63 FAD D fimimng external ARES asenin e i a a gees vant aasGeaceceerstas 12 63 7 16 Activate forced gain control for an external aXis eseecesrsereeressreerreress 12 75 7 17 Activate notch filter for an external axis eeeseeseeessesesressrseresressesrrssee 12 76 TS SOM Serve for extemal axis inre a ea A EER ERE ge 12 77 7 19 Defining the joystick di
417. rd 38001 Battery backup lost Battery backup on serial measurement board f on measurement system f lost since last power down or restart Check Check battery voltage during power off after 18 hours recharging in power on Check battery connection to serial measurement board Replace battery 38010 Serial Board not found Serial measurement board f on measurement system f not found Check Check system configuration parameters Check connections and cables to serial measurement system Replace serial measurement board 38012 Serial Offset X Error Offset error in X signal on serial measurement board f on measurement system f Check Replace serial measurement board 16 43 System and Error Messages 38013 Serial Offset Y Error Offset error in Y signal on serial measurement board f on measurement system f Check Replace serial measurement board 38014 Serial Linearity Error Linearity error in X Y signal difference on serial measurement board f on measurement system f System may still operate with warning System will not function with error Check Replace serial measurement board 38015 Serial Linear X Error Linearity error in X signal on serial measurement board f on measurement system f Check Replace serial measurement board 38016 Serial Linear Y Error Linearity error in Y signal on serial measurement board f on measurement system f Check Replace serial measuremen
418. rd processing program It can also be loaded into the robot program memory and then read on the teach pendant For information on how to load programs from diskette see Chapter 8 Program ming and Testing 2 Other Manuals Before using the robot for the first time you should read Basic Operation This will provide you with the basics of operating and programming the robot Basic Operation is included in this manual see Chapter 4 The Product Manual describes how to install the robot as well as maintenance pro cedures and troubleshooting This manual also contains a Product Specification which provides an overview of the characteristics and performance of the robot The RAPID Reference Manual contains a detailed explanation of the programming language as well as all data types instructions and functions They are described in alphabetical order for your convenience If you are programming off line the RAPID Reference Manual will be particularly useful in this respect 3 How to Read this Manual Before you start reading through this manual it is essential that you read Chapter 3 Safety This tells you what you should or should not do to avoid injuring yourself or someone else Chapter 4 Basic Operation is an introduction to the basic operation and program ming of the robot It is recommended to be used as a tutorial together with a robot or the PC software QuickTeach You will find a general description of the robot such as w
419. rd with more memory 60023 Limit ModPos You cannot modify this position because limit modpos is activated with ABS ABS absolute mode means that the original position should be saved This cannot be done while tuning Check If executing stop the program Modify the position in the Program Window This will create an original position This position will thereafter allow tuning Limits are set by Limit Modpos 60024 Outside Limits The change is either outside the internal limit 10 mm or exceeds the limit set by limit modpos parameter Max Trans Check A single change cannot exceed 10 mm Do the change in smaller steps If Limit Modpos is set and the parameter Max Trans is less than 10 mm this parameter has to be changed User s Guide Base Ware OS 3 1 60025 Name not allowed The name already exist or is a reserved word Check Please use an other name See list of reserved words in Rapid manual 60026 Program memory soon full Save program or take other appropriate actions 60027 Cannot calc tool frame It is not possible to calculate the tool frame with the selected approach points Check Select new approach points as accurate as possible 60028 Cannot show all signals Only d signals out of d will be listed 60029 Cannot show all units Only d units out of d will be listed 60030 Too many signals Too many signals are selected for the Most Common list Only the first d
420. re the manipulator is moving at high speed Proc ess update time should be kept small to get the best performance When the manipu lator is moving slowly Process update time is not critical Choose Topics Manipulator e Choose Types motion system e Press Enter e Select Process update time and change its value e Press OK to confirm 7 24 Installation optimization of drive system parameters A 12 86 When installing the software all the drive system related parameters are set to their nominal values If the following parameters are adjusted according to the installation cable length peak power mains tolerance cycle times can be shorter Changes outside the range of the installation may violate robot performance Mains tolerance The mains tolerance is set to 10 15 on delivery If the minimum tolerance is less than 15 cycle times can be shorter if the parameter is changed User s Guide System Parameters Choose Topics Manipulator e Choose Types Mains e Press Enter e Select Mains tolerance min and change its value e Press OK to confirm Maximum transformer power The software assumes a predefined maximum power consumption that together with the mains tolerance gives a certain DC link voltage If the application needs less than this power the DC voltage will always be higher and the cycle times can be shorter if the parameter is changed Choose Topics Ma
421. re y Copy Paste OptArg ModPos gt Test Figure 11 The instructions are chosen from an instruction pick list e Choose the desired instruction using one of the following alternatives Using the numeric keyboard press the number displayed in front of the appropriate instruction in the pick list Select the pick list by pressing the List instruction and press Enter lt key Then select the desired Use 0 on the numeric keyboard to scroll down to the lower part of the pick list or to the next pick list If the instruction has no arguments or if these are automatically set the instruction is ready for use right away If the instruction has arguments that cannot be automatically set a dialog box will appear in which you can specify the value of the instruction arguments The argument is marked with a in front of it see Figure 12 User s Guide Programming and Testing SS ayy Instruction Arguments Add lt EXP gt lt EXP gt Data 1 3 New counter_a counter_b regl reg2 reg3 reg4 Next Func More Cancel OK Figure 12 The dialog box used to define arguments In this example the instruction Add is programmed The argument can now be defined in four different ways by entering a numeric value directly using the numeric keyboard by choosing data in the lower part of the dialog box New the first alternative in th
422. recorder record the values of speed and torque_ref for the external axis 2 Use test positions for Nominal acceleration Run the motion and check the value of torque_ref for the torque limit Adjust the value of Nominal acceleration upwards or downwards in increments of 0 5 until the torque_ref signal shows that the axis does not reach the torque limit Reduce the final value by 10 to allow for variations in the mechanical system over a period of time 3 Use test positions for Nominal deceleration Run the motion and check the value of torque_ref for the torque limit Adjust the value of Nominal deceleration upwards or downwards in increments of 0 5 until the torque_ref signal shows that the axis does not reach the torque limit Reduce the final value by 10 to allow for variations in the mechanical system over a period of time Final tuning of Kp Kv and Ti If the axis has a variable moment of inertia Kp and Kv and Ti should be tuned with the maximum value for the moment of inertia Program two test points with the following requirements Velocity Choose a velocity that is approximately 25 of the maximum speed of the external axis The speed must be low enough to guarantee that the axis does not encounter the current limit but high enough to prevent friction from affecting the result Distance The distance should be chosen to ensure that the axis stabilises at the programmed velocity before deceleration starts e Using the chart r
423. rections for the robot and external manipulator 12 78 User s Guide User s Guide 7 20 Defining the joystick directions for a single external aXxiS eee 12 80 7 21 Defining kinematic parameters for general kinematics 0 0 0 eee eeeeeeeeeeee 12 81 7 22 Seryo parameters s s afs cazontsacics i a E E a E a aai 12 83 723 O PU OP Za O a O aaa 12 84 7 24 Installation optimization of drive system parameters cceeeeeeeteeeeeees 12 86 T3 File M har ioiscicisceses ces caicesctuiccstccecasionts candaun sees teazvacectievae sds ecieeasseanine 13 1 1 Program Data Storage scoccesascsy cess cevocccscesvacossevnccoscaevcevascosees seentwaseenacspsvonacseveones 13 3 2 The File Manager Window siisicssiccsescdsieccevescdcaesdesectvesdiouesdctesscussdisccciecnstsesaddenteas 13 4 2 1 CHOOSE A dree O 2 25 ee BOG BE Te Ge I 13 4 2 2 Viewing file informationssida aadesssecaseaes 13 4 3 Creating or Moving Files and Directories essseessocesooesooesoccsssccssocesocesoosesseessee 13 5 3 1 Creating a hew directory 1 55 sccvsusessiwesoenaQetstas een E EE A ES iA eS 13 5 3 2 Renaming a file or a directory esseeesseeeeseessessseseseressseessressersseeesseessseessres 13 5 3 3 Deleting a file or directory scseisscecssvsduarsccessseedsanscondsetabenccoaanscadenedeedbeavesateetens 13 6 3 4 Copying files and directories s sesesseeesseessessseeeseesseeesseesseesseeeseressseessres 13 6 3 5 Moving files and DireCtOme ss a
424. reloaded e Choose Types Tasks All specified tasks will be listed see Figure 21 File Edit Topics Types System Parameters Controller Tasks Task Prog Type 1 3 MAIN 0 NORMAL SUPERVISION 1 SEMISTATIC GUN 2 SEMISTATIC Add Figure 21 All available tasks e Select the task to be changed and press Enter or add a new one by pressing Add e Select the desired parameter and change its value e Press OK to confirm 12 42 User s Guide Parameter Task Prog Type Task in foreground Main entry BindRef TrustLevel System Parameters Description The name of a task max 16 characters The program number Program no 0 is reserved for the normal robot program which is the only one that may include motion instructions Controls the start stop and system restart behaviour NORMAL The task will react on START STOP requests given from the teach pendant or other sources STATIC The task will be started from the beginning at the first warm start after a cold start and automatically restarted at the current position at all other warm starts SEMISTATIC The task will be restarted from the beginning at all warm starts Program no 0 must be of type NORMAL The other tasks should be of type STATIC or SEMISTATIC The name or program number of a task that should run in foreground the of this If 1 or an empty string is set for this parameter it will r
425. ressed Fetch the part from In feeder Leave part in the machine Start the actual processing Fetch the part Leave the part on Out feeder Update operating statistics Stop production for the day The routines process_part fetch_machine and leave_part are not included in this example 2 3 Operating the gripper 17 8 A tool gripper1 defines the TCP and the weight of the gripper This tool data is defined in the system module USER In this way the tool is always present in memory irrespective of which program is loaded The gripper is controlled by electric bistable air valves which means that there is one signal that controls the grip action and another that controls the release The names of the signals are defined in the system parameters as grip and release1 There is also a signal gripok that is high if a part is held by the gripper This signal is used to check if the gripper has gripped a part correctly A load data payload is defined which describes the load held by the gripper The best possible motion performance is achieved if the correct load is always specified As the gripper grips and releases parts several times during the course of the program it is best to set up separate routines for this which can be called by the program For example Routine grip_part Comments Reset release 1 Set grip Grip the part WaitTime 0 5 Wait 0 5 s IF DInput gripok 0 THEN If error no part in the gripper
426. revent these appearing e Open the Log window by choosing View Log e Choose the Common log by selecting it and pressing the Msg function key or press Enter Now error alert boxes will not be shown Error messages will be either displayed directly if you chose Special Update log on Event or following a command in the log if you chose Special Update log on Command 3 9 Saving log messages on diskette or some other mass storage device e Open the Log window by choosing View Log e Select the log that you wish to save and choose File Save As A dialog box will appear displaying the contents of the current directory see Figure 4 User s Guide 14 7 Service ia ee ne Save log messages as Name ELOG Mass storage unit Massmemory unit flpl ROBOTL lt Directory level 4 5 as Go up 1 level OPLOG Event log SYSLOG Event log COMLOG Event log TEST Directory Unit New Dir Cancel OK Figure 4 Dialog box for storing logs e If necessary change the mass storage unit by pressing the Unit function key until the cor rect unit is displayed To store on a diskette choose flp1 e Select the Name field press Enter 4 and enter the new name in the dialog box that appears Choose OK to confirm e Select the directory to which the log is to be saved You can move to the next directory level by selecting the desired directory or upwards and pressin
427. revented 3 10 User s Guide Safety 8 2 Tools workpieces It must be possible to turn off tools such as milling cutters etc safely Make sure that guards remain closed until the cutters stop rotating Grippers must be designed so that they retain workpieces in the event of a power fail ure or a disturbance of the controller It should be possible to release parts by manual operation valves 8 3 Pneumatic hydraulic systems Special safety regulations apply to pneumatic and hydraulic systems Residual energy may be present in these systems so after shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from falling due to gravity 9 Risks during Operation Disturbances If the working process is interrupted extra care must be taken due to risks other than those associated with regular operation Such an interruption may have to be rectified manually Remedial action must only ever be carried out by trained personnel who are familiar with the entire installation as well as the special risks associated with its different parts The industrial robot is a flexible tool which can be used in many different industrial applications All work must be carried out professionally and in ac
428. ripheral equipment may also be started Make sure that everything is ready for program execution to begin and that nobody is in the safeguarded area around the robot Starting the program incorrectly can injure someone or damage the robot or other equipment e Set the robot into MOTORS ON mode by pressing the enabling device e Press the function key Start for continuous or cycle execution mode If you want to execute step by step press the function key FWD or BWD instead When Hold to run is active the following is applicable press the Start key release it and press the Hold to run key Keep this key depressed while the program is running otherwise the program will stop see Figure 22 The start key should only be pressed once after each MOTORS ON the Hold to run key can then be used to start and stop program execution User s Guide Programming and Testing Hold to run Enabling device Start FWD BWD Modpos Instr gt l Press the Hold to run key within 3 s after you pressed the Start key If a longer time elapses you must start A again with the Start key Figure 22 The Hold to run key is located on the side of the teach pendant 6 6 Stopping program execution When Hold to run control is enabled e Release the Hold to run key When Hold to run control is NOT enabled e Press the Stop key on the teach pendant If the program
429. roduction window will appear after a few seconds The robot is started up with the same status as when the power was switched off The program pointer remains unchanged and all digital outputs are set to the value before power off or to the value specified in the system parameters When the program is restarted this is considered to be a normal stop start The robot moves back slowly to the programmed path if there is a deviation and then continues on the programmed path Motion settings and data are automatically set to the same values as before power off The robot will continue to react on interrupts The mechanical units that was active before power off will automatically be activated at program start The arc welding and spot welding processes are automatically restarted But if a change of weld data has just been executed this new data will be activated too early on the seam Limitations All files and serial channels are closed this can be handled by the user program All analogue outputs are set to 0 and the Soft servo Tune servo is set to default values can be handled by the user program WeldGuide cannot be restarted User s Guide 5 3 Starting up Independent axes cannot be restarted If the power failure occurs during a movement in an interrupt routine or error handler the restart of the path is not possible If the program execution is in a part when the CPU is very busy there
430. rogram Running Mode A program can be run in either of the following two ways Cont continuous execution Cycle the program is executed once You can change the program running mode in the Running mode field e Select the middle part of the display by pressing co e Select Running mode see Figure 4 User s Guide 11 5 Production Running Program list MoveL p3 v500 z20 tooll Speed 75 Running mode Continuous Program running mode 2 39 MoveL pl v500 z20 tooll gt MoveL p2 v500 z20 tooll Set dol Set do2 Cont Cycle Figure 4 The function keys are used to select the different program running modes e Press the desired function key Cont or Cycle ill e To return to the program list part use t 5 Starting the Program A When the program is started the robot and any peripheral equipment will start to move Check that all preparations have been made for program execution Make sure that the workcell is clear of all personnel before starting the robot If NOT LOADED is displayed on the program status line then a program must be loaded see Reading a Program on page 4 If a program is loaded and is executable STOPPED will be displayed on the program status line and the program can be started e Press the function key Start Start When a program is executing t
431. rogram or stop program execu tion before issuing command 50154 Command not allowed SingAreaWrist mode interpolation is not supported for the IRB6400C robot Check Replace SINGAREAWRIST instruction with SINGAREAOFF 50155 Power fail restart failed Not possible to restart the Move instr before RestoPath ActUnit Wait or Stop instr Check Make program free from MOTION WARNING 50146 Restart limitation by changing the Move instr to finepoint Move the start point and start a new movement 16 82 50156 Independent joint error Joint s is not configurated as an independent joint Check Modify the program or configurate the joint as an independent joint 50157 Corr vector warning Sensor correction vector X calculations failed due to previous error 50158 Sensor process missing Sensor process missing during initialization Named sensor process s could not be found or initialized Check Check process name in motion and process configuration files 50159 No external process Attempt to coordinate motion or calculate position of single s without an external process Check Check process name in motion and process configuration files 50160 Cannot reach position Programmed position of indep joint s is outside working range and thus cannot be reached Check Change the position Check the joint working area limits Check the used work object 50161 Singularity area Robot is close to
432. rogramming and Testing 8 30 8 1 Selecting an instruction or an argument A complete instruction or a single argument can be selected before a command is given to change the program If you wish to change a single argument it is often easiest to select the argument first If you wish to change a complete instruction you select the complete instruction Often e g when adding a totally new instruction it does not make any difference whether the complete instruction or an individual argument is selected To select a complete instruction Movement Choose Up one instruction ArrowUp O Down one instruction ArrowDown g To first instruction Edit Goto Top To last instruction Edit Goto Bottom To next page NextPage To previous page PreviousPage 4 If the cursor is moved to the first line in a compound instruction IF FOR WHILE or TEST all instructions including the last line e g ENDIF will be selected If ArrowDown is then pressed the instructions in the compound instruction will be selected one after the other Terminators e g ENDIF ELSE cannot however be selected separately When the cursor is moved upwards to a compound instruction ArrowUp can be used to select the instructions within that instruction and ArrowLeft can be used to select the complete compound instruction To select a number of instructions You can select a group of instructions that are in sequence e Selec
433. rom the main routine or from some other routine When a routine has been fully executed program execution resumes at the next instruction in the calling routine User s Guide 8 5 Programming and Testing 8 6 Data is used to define positions numeric values registers counters and coordinate systems etc Data can be changed manually but it can also be changed by the program for example to redefine a position or to update a counter An instruction defines a specific action that is to take place when the instruction is executed for instance moving the robot setting an output changing data or jumping within the program During program execution the instructions are executed one at a time in the order in which they were programmed System modules are programs that are always present in the memory Routines and data related to the installation rather than the program such as tools and service routines are stored in system modules 1 2 The Program window All program and testing is performed using the Program window e Press the Program key to open the window The Program window is actually made up of a number of different windows These can be chosen from the View menu Window title Used to Program Instr Program and change program instructions Program Routines Choose or create new routines Program Data Create or change data Program Data Types Choose data of a specific type Program Test Test programs Program M
434. ror Task 16s Alias name 16s is ambiguous Check At least one other object sharing the same name as the referred alias name is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40113 Name error Task 16s Global alias name 16s ambiguous Check Global type must have names that are unique among all the global types data global routines and modules in the entire program Rename the alias or change the conflicting name 40114 Type definition error Task 16s Type reference of alias name 16s is an alias type Check Check that the type of the component is correctly defined If so it could be a circular definition the type of a component could not refere to the its own record type 40115 Type definition error Task 16s Cannot determine type of alias 16s circular type definitions Check Check that the type of the alias is correctly defined If so it could be a circular definition the type of an alias could not refere to a record that use this alias as a component 16 60 40116 Reference error Task 16s Record component name 16s is ambiguous Check At least one other object sharing the same name as the referred component is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40117 Type definition error Task 16s Place holder for record com
435. ror Task 16s Execution stack overflow Check The program is too complex to execute Probably the program contains recursive routines 40223 Execution error Task 16s Fatal runtime error Check A fatal runtime error has occurred Fatal runtime errors causes immediate termination of execution See previous message for the actual cause 40224 Execution error Task 16s Illegal return code i from ReaL routine Check This is always caused by an internal error in the ReaL routine 40225 Execution error Task 16s Execution could not be restarted Check Execution could not be continued after power failure Restart the program User s Guide BaseWare OS 3 1 System and Error Messages 40226 Name error Task 16s Procedure name AOs is not a RAPID identifier excluding reserved words Check The procedure name must be a legal RAPID identifier not equal to any of the reserved words of the RAPID language Change the name expression 40227 Limit error Task 16s Runtime stack overflow Check The program is too complex to execute Probably the program contains recursive routines 40228 Execution error Task 16s Unhandled non fatal runtime error i Check A non fatal runtime error has occurred but was not handled by any ERROR clause See previous message for the actual cause 40229 Execution error Task 16s Unhandled raise error i Check An error was raised by a
436. routine declaration User s Guide 8 35 Programming and Testing e Make whatever changes you wish to make see Creating a new routine on page 10 e Choose OK to confirm the change s 8 8 Deleting an instruction or an argument e Select the instruction or the argument you wish to delete e Press Delete lt Note An answer must be given to the password check and confirmation dialog if they have been set to active in the configuration The default set up is no password but with confirmation If an argument is compulsory required it will be replaced by lt gt 8 9 Deleting a routine e Choose View Routines e Select the desired routine e Press Delete XII Note An answer must be given to the password check and confirmation dialog if they have been set to active in the configuration The default set up is no password but with confirmation 8 10 Undo latest action e Choose Edit Undo The command Undo performs an undo operation on the latest performed action in the window selected Undo is enabled in the Program Instr Test Data and Routine windows The Program Instr and Program Test windows share the same undo buffer The Data window and Routine window each have their own undo buffer The undo command line tells you which command is to be undone see Figure 31 If there is nothing to be undone or if the undo buffer has been lost the undo command is disabled This is shown as Undo
437. rror Current error Torque producing current lower than ordered Drive unit joint s DC link voltage s V Check Check DC voltage Check configuration Check motor cables 39220 Drive System Error Current error Torque producing current higher than ordered Drive unit joint s DC link voltage s V Check Check configuration Check motor cables 39221 Drive System Error Current error Non torque producing current bigger than allowed Drive unit joint s DC link voltage s V Check Check DC voltage Check configuration Check motor cables 39222 Drive System Error Current error The current is higher than max measurable due to short cirquit or unstabile current controller Drive unit joint s DC link voltage s V Check Check motor cables short cirquit Check configuration motor parame ters Replace drive unit User s Guide BaseWare OS 3 1 System and Error Messages 39230 Drive System Error Unknown drive unit type code joint s Read typecode d when expecting d Check Replace drive unit Check serial link 39231 Drive System Error Wrong program revision in drive unit for joint s Read revision d out of range Check Replace drive unit 39232 Drive System Error Drive unit CPU for joint s did not Start Check Replace drive unit 39233 Drive System Error Axis computer has detected too many consecutive communication errors from
438. rror Error in measurement system d when testing seriel link in loopback mode Check Replace robot computer board 33414 Loopback error Error in drive system d when testing seriel link in loopback mode Check Replace robot computer board User s Guide BaseWare OS 3 1 System and Error Messages 33415 Drive system error Error in the drive system d when testing seriel link in normal mode Check Check seriel link Check drive unit Check de link Check Replace robot computer board 34001 Bus error Unexpected bus error during a VME test Check Check VME boards 34002 Bus error Unexpected reply during a VME test Check Check VME boards 37001 Contactor activate Error Motor On contactor did not activate energize Check 1 Restart system 2 Check replace contactors M On AUX 3 Replace panel board 37002 DSQC306 not running Main computer software not downloaded or not running 37003 Main computer error Check Replace main computer board 37004 Main computer error Check Replace main computer board 37005 Main computer error Check Replace main computer board 37006 Main computer error Check Replace main computer board 37007 Main computer error Check Replace main computer board 16 41 System and Error Messages 37008 Main computer error Check Replace main computer board 37009 Main computer error Check Replace main computer board 37010 Main computer error Check
439. rror occurs because too many fly by points were placed very closely together or because of incorrect use of instructions e g a fly by point followed by a WaitDI instruction Normally Prefetch time should only be increased when the fly by point is really needed in the application When it is not really needed change the fly by point to a fine point There is a drawback when increasing the Prefetch time The difference between the position of the executed RAPID instruction and the current position of the manipulator will increase This means that after pressing stop during program execution the program counter on the teach pendant may show an instruction that has not yet affected the manipulator When starting again the manipulator will continue along the original path e Choose Topics Manipulator e Choose Types motion system e Press Enter e Select Prefetch time and change its value e Press OK to confirm CPU equalisation The parameter CPU equalisation affects the CPU load in terms of peak load versus average load When there is a CPU load problem indicated for example by 50082 Deceleration too long then one solution could be to use CPU equalisation to distribute the CPU load over time in some other way Sometimes a higher peak load can be acceptable as long as it occurs at a favourable moment in time Try changing CPU equalisation both upwards and down to find the optimal value e Choose Topics Man
440. rs is num Check the type of the operand 40028 Type error Task 16s Illegal type 18s for right operand of P DIV or MOD operator Check The only allowed type for the operands of the DIV and MOD operators is num Check the type of the operand 40029 Type error Task 16s Illegal type 18s for left operand of L lt gt or gt operator Check The only allowed type for the operands of the lt lt gt and gt operators is num Check the type of the operand 40030 Type error Task 16s Illegal type 18s for right operand of L lt gt or gt operator Check The only allowed type for the operands of the lt lt gt and gt operators is num Check the type of the operand 16 52 40031 Type error Task 16s Illegal type 18s for left operand of operator Check The allowed types for the operands of the operator are num pos and orient Check the type of the operand 40032 Type error Task 16s Illegal type 18s for right operand of operator Check The allowed types for the operands of the operator are num pos and orient Check the type of the operand 40033 Type error Task 16s Illegal type 18s for operand of NOT operator Check The only allowed type for the operand of th
441. rt point pstart for searching Make a linear search from the start position to an end position pend When a digital input di is set the robot should stop the movement and draw a figure triangle the position of which will depend on the search point psearch The figure triangle is programmed with no displacement active and with the first posi tion in ptriangle User s Guide Calibration The program may look like MoveL pstart v200 fine tooll SearchL Stop dil psearch pend v100 tool1 PDispOn ExeP psearch ptriangle1 tool1 triangle PDispOff etc pstart psearch pend ptrianglel io i displacement vector 8 11 Creating a new displacement frame Open the Program Data Types window by choosing View Data Types e Select the type pose and press Enter e Create the new displacement frame using one of the following alternatives alt 1 Press the function key New The displacement frame will then have no translation or rotation alt 2 Select an existing displacement frame and press the function key Dupl The displacement frame will then be the same as the one duplicated A window appears displaying the name of the data e If you want to change the name press Enter 4 and specify a new name e Press OK to confirm 8 12 Manually updating a displacement frame e Open the Program Data Types window by choosing View Data Types e Select the t
442. ry IO Parameters ROBOT Parameters Unit Cancel OK Figure 4 The dialog box used to load parameters e If necessary change the mass storage unit by pressing the Unit function key until the cor rect unit is displayed To load parameters from a diskette choose flp1 e Select the directory from which the parameters are to be loaded You can move to the next directory level by selecting the desired directory or upwards and pressing Enter e Choose OK to confirm the load An alert box will be displayed during reading After this the robot must be restarted see Generating a restart on page 4 User s Guide 12 7 System Parameters 12 8 User s Guide 3 Topic IO Signals The following parameters are found under the topic IO Signals Specification of all I O units System Parameters Name and characteristics of input and output signals Groups of digital signals Cross connections List of all available unit types System signals e Choose Topics IO Signals 3 1 Defining I O Units e Choose Topics IO Signals e Choose Types IO Units All defined units will be displayed as shown in Figure 5 File Edit Topics Types System Parameters IO Signals IO Units Name Address Type Bus 3 3 PANEL 10 d331 BASE d327_11 11 d327 BASE d328_12 12 d328 BASE Add Figure 5 System parameters of the type IO Units e Select the appropriate I O unit to be chang
443. s 71131 Could not mount directory DescriptionReason Mounting directory s on the computer s failed Protocol s Check 1 Check the NFS server setup 16 98 71132 Battery supervision block DescriptionReason The battery superviosion is blocked becaurse a power off on is made Will be released s Check 71133 Battery not charged DescriptionReason The battery is not charged after the first charging state Check 1 Check that the batlow signal is connected to the DSQC347 2 Check the battery connections 3 Check the battery 71134 Parameter value not found DescriptionReason Unit s refers to values s that don t exists Check 1 Check unit configuration 71135 Parameter defs not found DescriptionReason Unit type s refers to parameter definitions s that don t exists Check 1 Check unit type configuration 71136 Parameter Error DescriptionReason Parameter s could not be downloaded to unit s Check 1 Check unit configuration 2 Check precceding error messages 71137 Error code from unit DescriptionReason The following error was returned Jos Check 1 Check unit parameter configuration User s Guide Base Ware OS 3 1 71138 Unknown Parameter DescriptionReason s is not a valid parameter for unit s Check 1 Check unit parameter configuration 71139 Access error from IO DescriptionReason Cannot Read or Write sign
444. s OAIHNDUBWNHE Command Most Common All Signals Digital In Digital Out Analog Groups Safety T O Units User s Guide The Inputs Outputs Window Used to go to a specific line in the list go to the first line in the list go to the last line in the list Used to view see page 7 4 the most common list all user signals all digital inputs all digital outputs all analog signals all groups of digital signals all safety signals all I O units The Program Window Quick Reference 3 The Program Window 3 1 Moving between different parts of the program Program memory m Program View Data f View Main Routine y View Routines Current routine x Main a View Routine Data sik routine Data routines View Instructions a Instructions g View Error Handler Error Handler View Modules System modules j 18 6 User s Guide Quick Reference The Program Window 3 2 General menus 3 2 1 Menu File File 1 Open 2 New 3 Save Program 4 Save Program As o Print 6 Preferences 7 Check Program 8 Close Program Ko Save Module 0 Save Module As Only shown in the module window Command Open New Save Program Save Program As Print Preferences Check Program Close Program Save Module Save Module As User s Guide Used to read programs from mass storage
445. s not of array type Check Only data that have been declared to be arrays may be indexed Remove the index or indices or declare the data to be an array User s Guide Base Ware OS 3 1 40018 Type error Task 16s Data 18s 18s is not of record type Check Components are only available for data of record type Check the type and name of the referenced data 40019 Limit error Task 16s Error when creating the persistent variable internal error code 1 16s Check An error occurred when the persistent was to be inserted into the shared database Probably the database is full Ref to system parameter AveragePers 40020 Data declaration error Task 16s Expression not constant expression 16s not constant Check Expressions contained within data declarations must be constant expressions Make sure the expression does not contain any variable or persistent reference or function call 40021 Instruction error Task 16s RETURN from function must have an expression Check A RETURN instruction within a function must specify a function value to be returned Add a value expression User s Guide BaseWare OS 3 1 System and Error Messages 40022 Type error Task 16s Illegal combination of operand types 18s and 18s for operator Check The allowed type combinations for the two operands of the operator are num num num pos pos
446. s displayed on the same line cannot exist simultaneously in an instruction When such an argument is added the corresponding mutually exclusive argument is automatically removed An optional argument can also be removed by selecting the desired argument and pressing the function key Remove e Choose OK to confirm the change 8 6 Changing the structure of an IF FOR or TEST instruction e Select the complete instruction that is to be changed e Press Enter A dialog box appears displaying the structure that the instruction can have Structure parts not included in the instruction are enclosed within square brackets see Figure 30 a Instruction Arguments 4 6 IF expression Statement list ELSE ELSEIF ENDIF Add Remove Cancel OK Figure 30 The dialog box used to change the structure of an IF instruction e Add part of the structure by selecting the desired part and pressing Add e Remove a part of the structure by selecting the desired part and pressing Remove e Choose OK to confirm the change Note If you want to add more than one ELSEIF or CASE these can be added in the Program window using Copy and Paste Different CASE statements such as CASE 1 2 3 can also be added using Copy and Paste 8 7 Changing the name or declaration of a routine e Choose View Routine e Select the desired routine e Press the function key Decl A dialog box appears displaying the
447. s ambiguous Check Modules must have names that are unique among all the global types global data global routines and modules in the entire program Rename the module or change the conflicting name 16 53 System and Error Messages 40046 Name error Task 16s Parameter name 16s ambiguous Check Parameters must have names that are unique within the routine Rename the parameter or change the conflicting name 40047 Name error Task 16s Persistent name 16s ambiguous Check Program data must have names that are unique within the module Rename the data or change the conflicting name 40048 Name error Task 16s Routine name 16s ambiguous Check Routines must have names that are unique within the module Rename the routine or change the conflicting name 40049 Name error Task 16s Variable name 16s ambiguous Check Routine data must have names that are unique within the routine Program data must have names that are unique within the module Rename the data or change the conflicting name 40050 Type error Task 16s Operand types 18s and 18s for binary or operator not equal Check The two operands of the and operators must have equal type Check the operand types 16 54 40051 Type error Task 16s Operand types 18s and 18s for or lt gt operator not equal Check The two operands of the and lt
448. s can be stored in their entirety or stored as individual parameter topics for example on a diskette To save all parameters The parameters are always saved to a directory in the form of a separate file for each topic e Choose File Save All As A dialog box appears displaying all files in the current directory see Figure 3 Save All Parameters Select a directory to save to axe _ Mass storage unit Massmemory Unit flp1 PARAM Directory level 1 4 a Go up 1 level BACKW18 Directory IO Parameters ROBOT Parameters Unit New Dir Cancel OK Figure 3 The dialog box used to store parameters e If necessary change the mass storage unit by pressing the Unit function key until the cor rect unit is displayed To store on a diskette choose flp1 e Select the directory to which the parameters are to be saved You can move to the next directory level by selecting the desired directory or upwards and pressing Enter o Create a new directory by pressing the New Dir function key Specify the new direc tory name in the dialog box that appears Choose OK to confirm e Choose OK to confirm the save To save an individual parameter topic e Choose File Save As A dialog box appears displaying all the previously saved parameters in the current directory User s Guide System Parameters e If necessary change the mass storage unit by pressing the Unit func
449. s movements The field that indicates the various deflections of the joystick displays how the principal joystick directions are linked to axes or coordinate directions See the example in Figure 3 Note The relationship between joystick deflection and robot movement can be changed in the system parameters All the figures in this manual are related to standard setup 6 4 User s Guide Jogging Figure 3 The direction of movements associated with each joystick deflection is displayed in the Jogging window 1 4 Locking of joystick axes It is possible to disable joystick deflections in certain directions e Select the field Joystick lock see Figure 4 e Select the joystick axes to be disabled by pressing the corresponding function key Enable all axes by pressing the function key None 4 9m A E z 12 8 m Q1 0 7071 m Coord Base Q2 0 0000 m Tool tool0 Q3 0 0000 m Wobj wobj0 Q4 0 7071 m Joystick lock tv xz y Incremental No y5 gt None ty 5e lt gt Figure 4 A joystick with disabled up down and rotational deflection 1 5 Motion Supervision Itis possible from the jogging window to turn motion supervision collision detection on and off This will only affect motion supervision during jogging e Choose Special Motion Supervision A dialog box appears displaying the setting for motion supervision see Figure 5 User s Guide 6 5 J
450. s on a diskette User s Guide 13 3 File Manager 2 The FileManager Window e Press the Miscellaneous key Select FileManager in the dialog box that appears e Press Enter The FileManager window will be displayed see Figure 2 File Edit View Options FileManager Current unit 1p1 WELDINGS TEST Current directory Name Type Date Latest change 2 12 a Go Up One Level PROC1 Program 1993 05 28 PROC2 Program 1993 05 09 Files PROCFUNC Program Module 1993 05 01 WDATA Program Module 1993 05 01 WTOOLS Directory 1993 05 01 RESULTS Directory 1993 06 01 Up gt Figure 2 The FileManager window displays all files in a directory Choose the desired unit from the View menu Diskette View flp1 RAM disk View ram 1disk 2 1 Choosing a directory e Select the desired directory e Press Enter The directories and files located in the chosen directory will be displayed The next directory above this can be selected by moving to the top line in the list and then pressing Enter or by using the Up function key 2 2 Viewing file information e Select a file in the list and press Enter The following information will be specified the name and type of the file the size of the file in bytes the date and time when the file was last changed e Choose OK to term
451. s positioned relative to the tip Max Error The maximum error for one approach point The calculation result can be saved in a separate file for later use in a PC However this file cannot be read by the robot e Press the function key File e Specify a name and a place to save the result e Choose OK to confirm the save e If the estimated error is acceptable press OK to confirm the new tool coordinate system not acceptable redefine by pressing Cancel The definition is now complete but before proceeding with other tasks verify it by linearly jogging in the tool coordinate system and by reorienting the TCP If the tool has been stored in a system module save this module 7 5 Stationary tool When using a stationary tool the robot is holding the work piece and the tool is sta tionary in the room In this case the TCP coordinates are related to the world coordinate system and the work object i e the user coordinate system is related to the wrist coordinate system Creating a new tool e The tool is created as described in previous chapters User s Guide 10 33 Calibration 10 34 e The component robhold is changed to FALSE Creating a corresponding work object When using a stationary tool it is also necessary to use a work object held by the robot e The work object is created as described in Creating a new work object on page 36 e The component robhold is changed to TRUE Methods for defining the tool
452. s the correct program The Program name is displayed in the right hand upper corner of the window e Choose View Info to open the window Production Info To start the program see Starting the Program on page 6 If the Status field indicates NOT LOADED then you must load a program see Reading a Program on page 4 Field Routine Status Speed Running mode Program list Program pointer User s Guide Indicates The subprogram that is being run NOT LOADED no program is loaded STOPPED a program is loaded and it can be executed PP is set RUNNING program execution is in progress NOT EXECUTABLE a program is loaded but cannot be executed The chosen speed correction as a percentage continuous execution the program is executed once Continuous Cycle The part of the program that is being run The instruction to be executed when Start is pressed 11 3 Production Running 2 Reading a Program A program can be read from a diskette or from the robot s mass memory To open a program do as follows File Edit View 1 Load Program e Choose File Load Program The following dialog box will appear see Figure 2 R Open Select a Program to load Massmemory unit flpl1 ROBOT1 4 5 sa Go up 1 level Program list WELD1 Program WELD2 Program WELDPIPE Program TEST Directory Cancel OK Unit Figure 2 The dialog box displays a list of all av
453. sages related to the control program The messages related to defective hardware components Any messages that appear when moving the robot or other mechanical units Any messages displayed during program execution Any messages that appear when using the teach pendant The messages related to I O and communication User defined messages by using the instruction ErrWrite The messages related to the arc welding process The messages related to the spot welding process Internal errors does not usually contain any messages The window will display information on all logs in the robot see Figure 2 File Edit View Special Service Log No of messages eee _ Time of most recent Messa gee message 4 9 Log list el Name Latest Common 10 0810 20 30 32 Operational 20 0810 20 25 14 System 0 Hardware 1 0810 20 30 32 Motion 3 0810 19 15 12 Program 0 Operator 4 0810 19 15 12 I O amp Communication 0809 12 30 00 Msg gt Displays the messages in selected log Figure 2 The Service Log window displays all existing logs User s Guide 14 5 Service 3 4 Viewing a message in a log e Open the Log window by choosing View Log e Choose the log you wish to look at by selecting that log from the list and pressing the Msg function key or press Enter The window will display all messages for the log that you choose see Figure 3
454. saved in a separate file for later use in a PC e Press the function key File e Specify a name and a location where to save the result e Choose OK to confirm the save If the estimated error is acceptable press OK to confirm the new axis definition Now the next axis can be defined if necessary not acceptable redefine by pressing Cancel e Choose File Restart in the Service window to activate the user frame The user frame definition is now completed but before proceeding with other tasks verify it by jogging the mechanical unit in coordinated mode Note The user frame is stored in the system parameters as the base frame of the external mechanical unit The user frame in the corresponding work object is therefore not used User s Guide 10 27 Calibration 7 Defining Tools 10 28 The position of the robot and its movements are always related to its tool coordinate system i e the TCP and tool orientation see Figure 23 To get the best performance it is important to define the tool coordinate system as correctly as possible For more information see the RAPID Reference Manual Motion and I O Principles Z X Figure 23 The tool coordinate system for a gripper A tool coordinate system can either be defined manually or the robot can be used as the measuring tool Manual definitions can be used if accurate data for the dimensions of the tool is available or if minor corrections are to be done 7 1 Creating
455. scssssscces O 9 Backup and Restore ssccissstsisvcesastescivadsisacscicdsvacissnsaasuiscssaanaccasensedsiuaeaceunaadeatesrsaiserasacsasivaa LO 9 1 Perform a Backup sieisciesssk pcasetavsdandsagasiiasscdptates aud cdean sd a ao a R an 10 9 2 Perform a Restores innin a Bure A RA E EE a EA 11 10 Perform Restart ccesccssistsciieccssitecistesscecsestescealececetcoussceasdcececcesessceesscecccassdedseassvacacavcvesse LL User s Guide 14 1 Service 14 2 User s Guide Service Service The Service window is used to obtain information on the robot system view and change logs e g error log calibrate the measuring system for the robot and external axes commutate the motors for the robot and external axes set the date and time For more detailed information on service maintenance and troubleshooting see the Product Manual 1 The Service Window e Press the Miscellaneous key to open the Service window e Select Service in the dialog box that appears e Press Enter lt The service window comprises a number of different windows Window title Used to Service Date amp Time Change the current date and time Service Logs View logs Service Calibrate Test Calibrate the measuring system for the robot or external axes Service Commutate Test Commutate the motors for the robot or external axes Frame Definition Define base or user coordinate system Two Axes Definition Define user frame for a two
456. se OK to confirm the change e Add instructions between THEN and ELSE and between the ELSE and ENDIF by selecting the empty instruction lt SMT gt and choosing the desired instructions from the pick list User s Guide 9 13 The programming language RAPID If you want to remove the ELSE part of the instruction e Select the complete IF instruction and press Enter lt A dialog box will appear displaying the possible structure of the instruction Structure parts not included in the instruction are enclosed within square brackets see Figure 15 SSS SSS SSS Instruction Arguments 4 6 IF Expression Statement list ELSEIF ELSE End Add Remove Cancel OK Figure 15 The dialog box to change the structure of an IF instruction e Select ELSE and press Remove e Choose OK to confirm the change 5 Assigning a Value to Data Registers An assignment instruction contains the following information information on the data to be changed information on the desired value which may be a complete expression e g reg 5 reg2 Data to be changed aa a regl 1 The following instructions can be used to perform simple calculations on register variables clears a register increments by 1 decrements by 1 adds a value 5 to a register 9 14 User s Guide The programming language RAPID To program an assignment instruction e Call up the correct instructio
457. se injury or damage even if all f The above information regarding safety must not be construed as a warranty by safety instructions have been complied with 14 Related Information Described in Installation of safety devices Product Manual Installation and Commissioning Changing robot modes User s Guide Starting up Limiting the working space Product Manual Installation and Commissioning User s Guide 3 13 Safety 3 14 User s Guide Basic operation CONTENTS Page L MUMEV OC ENON isis eshte ncn scediecasndeassecsatedentcscehaenbenesanseneedetacadssnncsonlaseabiadeanguimeunersbaannucshntastelia oO FAS AL OUY EE tested cuss E A E eevee RRR I EE 3 System O VERVIEW isccs cicesatieaeudacngecvvnccwavedateos casbusueseesaavonexducossevacceuvencauevauneeneuebeaneusenameunmeuie d RE 2 Te et Paice ear rath tee en CT E dE POI reer ne OPP RE ne ac ore er re 7 SD The manipulator sapiaiesivsdcads waacasvedenetcisseessania anna sua sadea da sededa EEEa e e 8 3 3 IE CONLEOLICR a5 ot erica dso sabbedeinn a a a a NG 8 SA Operator spanel ngeti t iegdbes aes deavatedoten i hese esi 9 Ds TEACH pendant eunana a a a a a a aa 10 4 Starting the System sssi sssssse essensen ea asocias oaos ew eee LO 5 Working with Windows esssesssecssocesocecooesoccssocesocecooseooesooeessocesoceeooeeooessocessocesoossoosesossss L7 6 Jogging the Robot Using the Joystick csccsssscsssssccsssscssssccssssccssssscssssccsssssssssscces ZL Go
458. see Defining the Base Frame for the Robot on page 9 e Define the user frame of the mechanical unit see Defining the User Frame for a rota tional axis single on page 17 or Defining the User Frame for a two axes mechanical unit Method 1 on page 20 or Defining the User Frame for a two axes mechanical unit Method 2 on page 23 e Store all these definitions on a diskette by giving the command File Save All as in the System parameter window See chapter 12 in this manual e Create a new work object data and give it a name e g turntable In this work object change the component ufprog to FALSE indicating that the user object should be con nected to a moveable mechanical unit Also change the component ufmec to the name of the mechanical unit turntable must be written in text mode e If you want the object frame to be displaced relative to the user frame you may write the displacement in the x y z values of the oframe component of the work object For other methods see Defining a moveable object frame on page 40 e Activate the mechanical unit in the jogging window and check that the coordination is working satisfactorily This may be done by choosing Wobj in the field Coord and the work object e g turntable in the field Wobj and then jogging one of the mechan ical unit axes The robot TCP should also move following the moveable object coor dinate system e When programming it is important to have the coordinated work
459. see Figure 6 a Backup Include logs Destination directory 1p1 BAK0321 Saves all modules and system parameters to destination directory No Cancel OK Figure 6 The Backup view 14 10 User s Guide Service e Choose whether or not all logs are to be saved by selecting the Include logs field e Select a backup directory A default directory is suggested consisting of a prefix and current date BAKmmdd If you want to change directory press Enter 4 and select or create a new directory e Press OK to start the backup 9 2 Perform a Restore e Choose File Restore The Restore dialog will be displayed e Select a source directory generated by the Backup function Press OK to start the restore Warning Restore will remove and replace all existing parameters and modules in the system 10 Perform a Restart In the Service window a number of different restarts can be performed e Choose File Restart Normal restart Press OK Generate a cold start to be able to load in a complete new control program Enter the numbers 1 3 4 6 7 9 and press C Start Change language options or robot type Enter the numbers 1 4 7 and press I Start Activate arc welding parameters Enter the number 2 5 8 and press P Start Note When an arc welding parameter is activated the program memory will be erased So make sure that you have saved all programs on diskette Fore m
460. seisonesdcgasnseadeatectacessnteedtnsvacastesunsn deus avcavs eapuieaduncactebans 8 52 12 Error Handlin Go 5 03 cas eva oso ccs cones aco sera eve ee axe tv ens tod oo can oceayauanssobsasseeuieeniaeed 8 52 13 Using Modules wesccssscveccseacedeanesdvoacevaneseadtesaudcsuessnoueuonvedaanss canacvoaseocbucveenantoarelucneieee 8 54 13 What isa module 5 Gi Be Se a a A a aaa aaas 8 54 13 2 Choosing modules wis cciaciecsccesaseessieassavadessvedcacyauseaa ci dededade a es 8 55 13 3 Creating a New Module 22 te elon ath Ae ie Raed 8 56 13 4 Changing the name or declaration of a module eee eee eeteceeeeeeeeeenees 8 56 13 5 Reading a program module from diskette or some other type of MASS IVE TOE hs ais tie gle eh eden at A late cates ge hears E E len ees 8 57 13 6 Deleting program modules from the program eeceeeesseeesseceseeeeeeeenees 8 57 13 7 Listing all routines in all modules 0 eee eee eeeeeeeeeecneeeeneeeeeeeeaeesnaeens 8 57 13 8 Duplicating a routine from one module to another eeeeeeeeeeeeees 8 58 13 9 Listing all data in the current module ooo lee eee eeneeceeeeeteeeeeeeeaeeeaeens 8 58 13 10 Duplicating data from one module to another 00 0 ee eee eeseeeeeeeeeeeeeeees 8 58 13 11 Saving modules on diskette or some other type of mass memory 8 58 13 12 Calling up the complete module list oe ee eeeeeesee cree eeeeeeeeeeeaeeeaeens 8 59 14 PROLELOMCOS soa csuacesssttesiveveecciuctinienncesk sucpatesbacsndebese
461. ser frame The calculation result can be saved in a separate file for later use in a PC e Press the function key File e Specify a name and a location where to save the result e Choose OK to confirm the save If the estimated error is acceptable press OK to confirm the new user frame not acceptable redefine by pressing Cancel e Choose File Restart in the Service window to activate the user frame The definition is now complete but before proceeding with other tasks verify it by jogging the mechanical unit in coordinated mode Note The user frame is stored in the system parameters as the base frame of the external mechanical unit The user frame in the corresponding work object is therefore not used 10 22 User s Guide Calibration 6 4 Defining the User Frame for a two axes mechanical unit Method 2 This method will define the location of the user coordinate system of an Orbit type mechanical unit relative to the world coordinate system This user coordinate system should be used when a coordinated work object is used It should be noted that this method does not require that the kinematics relationship between two axes of the mechanical unit are defined in the robot system configura tion If this is a known factor another method can be used See Defining the User Frame for a two axes mechanical unit Method 1 on page 20 Figure 17 shows an orbit station with two rotational axes and a turntable mounted
462. serted after the fourth instruction 1 When the program test run is completed press the Instr function key The window in Figure 54 appears File Edit View IPL1 IPL2 Program Instr EXERCISE main 1 5 Moyer Te WSO Sa exovouh 0 MoveL v300 z10 tool0d MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 54 The Program Instruction window 2 Using the arrow keys up and down move the cursor to the fourth instruction in the program The new instruction will be inserted under the highlighted one 3 Select IPL1 Various The window in Figure 55 appears File Edit View IPL1 IPL2 Program Instr EXERCISE main Various 4 5 MoveL v300 z10 tool0 Lets MoveL v300 z10 toold 2 Comment MoveL v300 fine tool0 3 Load Horats Say SOO AE aliaKS toar 4 Unload MoveL v300 fine tool0 5 WaitDI 6 WaitDo 7 WaitTime 8 WaitUntil Copy Paste OptArg ModPos Test gt Figure 55 The pick list including the waitTime instruction 4 Select the desired instruction from the pick list in one of the following ways Using the numeric keyboard enter the number 7 shown in front of WaitTime see Figure 55 The numeric keyboard is illustrated in chapter 3 4 48 User s Guide Basic Operation Changing a Program Select the pick list by pressing the List key
463. sessseesseessessseresseeessressres 29 7 4 Using the robot to change the TCP and orientation of a tool eee eee eeeee 31 TD Stationary LOG seni arreire i aE seas ead bance e AEE EESE 33 8 Work Objects and Program Displacements eeseoessocssscessocesocesoosesocessccssocesoosssosssoeessose 35 Sle Generalaren iesi e a a MEE E A E A De eee ee ree 35 Bid BESTAS E08 E A A E E Scat EEEE EE 36 8 3 Creating a new work object ssesesseessssssesssesessstessressersseeeseeessseessressersseessseeessees 36 8 4 Manually updating the user and object coordinate system of the work object 37 8 5 Methods of defining a work ObDjeCt ue eeeccecssccecssececseececeeceeseceeseeeeseeeesaeeeenes 37 8 6 Using the robot to change the Work ObJeCt uc ceeeeceseeeceeeeeceeeeeceeeeecsteeeenteeeesaes 38 8 7 Defining a moveable object frames 0 1650 e OA a 40 8 8 How to use different work objects to get different displacements 08 40 8 9 How to adjust the program vertically using the object frame 42 8 10 Using program displacement 1 34ccccsdssaeeyscanseasacva nies sonssvensdepeesseuedccsalecabus teavanees 42 User s Guide 10 1 Calibration Page 8 11 Creating a new displacement frame eeeceeseceeneecesececeeececeeceeceseeeceeeeeeeeeeeees 43 8 12 Manually updating a displacement frame ee eee esse ceeeeeeeeeeeeeceeecneeeeeeeeneees 43 8 13 Methods for defining a displacement frame eee eeseeeeeeeeneecnaeceeeeeeeeeen
464. sessseessresserssessees 10 38 8 7 Defining a moveable object frame ce eeeeeescecesneeceeececeeececeeeeeeeeeeeeneeeees 10 40 8 8 How to use different work objects to get different displacements 10 40 8 9 How to adjust the program vertically using the object frame 0 10 42 8 10 Using program displacement cscceesseceeneeceeceeceeeeecseceeceeeeeneeeeneeeeaas 10 42 8 11 Creating a new displacement frame cc ceeceeceeececeeececeeeeeceteeeesteeeenaeeees 10 43 8 12 Manually updating a displacement frame cee eeeeeeceeeeceeeeeeeeeeeeeteeeees 10 43 8 13 Methods for defining a displacement frame 0 ei cee eee eseeeeseceeeeeeeeeenees 10 44 8 14 Using the robot to change a displacement frame eeceeeeeeeeeteeeetteeees 10 44 User s Guide 11 Production Running sseocecessosscccessssooeeccssssoccccesssosceccecssoosseesssssosoeesee 11 1 1 The Production Window sessseseesseesessossoessesooesoossecsoesoosseesoesoossossoesoossoesoesoossoessee 11 3 2 Reading a Program e ssesseessescorseesoesoesoosseesoesoossoesoesoossoesoesoossossoesoossossoesoossossoeee 11 4 3 Changing the Override Speed esessessesessossesossosseseosoesossossesossossesoosossessossesossoss 11 5 4 Changing the Program Running Mode sesessossesossossessoseesossossesossoesoscossesossossee 11 5 5 Starting the Program e seseessssessosessossesossossesossossescosossossossesosso
465. sh to view data of a type other than that displayed choose Data Datatypes and select the desired data type e Press the function key Decl A dialog box appears displaying the data declaration e Change the name and declaration as described in Creating Data on page 45 e Choose OK to confirm the change User s Guide 8 51 Programming and Testing 11 3 Deleting data e Choose View Data e Select the desired data e Press Delete X e Press OK to confirm the deletion 12 Error Handling Each routine has an error handler that can be programmed to deal with any errors that occur during program execution In this way some errors listed below can be dealt with automatically by the program when no search stop is obtained during a search when a file cannot be opened when there is division by 0 Other errors are listed under Data Types errnum Predefined Data RAPID Reference Manual The error handler is programmed in the normal way using RAPID instructions When an error occurs a jump is made to the error handler in the routine in which the error occurred If there is no error handler a jump is made instead to the error handler in the routine that called the routine in question A general error handler for the whole program can therefore be created in the main routine If there is no error handler when an error occurs program execution will stop and an error message will be displayed The
466. soft servo mode Kp and Kv are tuned such that Kp Kv Kp KV jormai Kp Kv ratio factor Ramp time Default time for activation of the soft servo The default value is 0 5 s When the soft servo is activated with an arbitrary softness 0 100 Kp and Kv are tuned such that the product Kp Kv is equal to a interpolated value between the max value Kp KV o mal K soft max factor and the min value Kp KV o mal K soft min factor User s Guide 12 77 System Parameters 12 78 Trimming of the soft servo parameters In most applications these parameters do not have to be trimmed and can be left at their default values K soft max factor determines together with Kp and Kv the softness at 0 If a soft ness of 0 yields too stiff a servo the factor should be reduced and it should be increased if 0 softness gives a servo which is too soft K soft min factor determines together with Kp and Kv the softness at 100 If a soft ness of 100 gives a too soft servo this factor should be increased and it should be reduced if 100 gives too stiff a servo A tuning algorithm can be e Determine a maximum axis movement for which the axis should not move with softness 100 Such a movement can be 0 1 rad for a rotating axis e Determine a minimum axis movement for which the axis should move with softness 100 Such a movement can be 0 2 rad for a rotating axis e Activate the soft servo with softness 100 and perform the two mo
467. sosssesoossosssesoossosssesoossosssessosese 3 13 User s Guide 1 1 4 Basic Oe Patni sess s2 ice soc cc ytesesccceonsdeast ic desisl cesccwcabsncesteceabacstseeccusadhdcasccusedess 4 1 5 Startins UY aksscs ae caccesecececicn Saye uassueceasiscaevts basstaecseueasevanss cucevasuasaneneeSedeusesucasecs 5 1 1 Switching on the Power Supply scccsssscssssccssssscssssccssssccssscsssssscssssssseesseees 5 3 1 1 Errors OM start up ashesi ier irta r e esas teagan t t aA ss 5 4 2 The Operator s Panel cssisccvesscascasesevce sovasovesessaveassudvesvecuavesavasvsvessscvesvensevsvntsssvens 5 4 3 Selecting the Operating Mode ccccssscssssssssssssssssssssssssssssssssssssssssssssscseess 5 4 3 1 Automatic mode production mode eee eeeeeeeeeeseeceseceseceseeeeseessaeenseeees 5 4 3 2 Manual mode with reduced speed programming mode ceceeeeeeeeeeee 5 5 3 3 Manual mode with full speed testing mode 0 eeeeeeeeeceteeeetteeeenaeeees 5 5 4 Switching the Power Supply to the Motors O11 cccssccssssccssssccssssccsssccseess 5 5 5 Emergency S COS scsi cuisaceceyiceenccswshec gat coeeacciseasedconseusncays goes seio o seses cas sausvancnccsnevetecss 5 6 5 1 Activating the emergency Stop button 20 0 eeeceeeeeeeceeeeeceeeeeceeeecsteeeeeaeees 5 6 5 2 Resetting Alter an emergency stop casi 5sccascossctsaissecavsqsecesstesoncsscteaaeee hboesmaag 5 6 6 The Teach Pendante csssicssosecssssesescsossscscisonsssssscssssssscos
468. sresseseessee 10 User s Guide 17 1 Program Examples 17 2 User s Guide Program Examples Simple Material Handling 1 Simple Material Handling 1 1 What the robot does The robot takes parts to and from a machine as in Figure 1 Machine In feeder Out feeder Figure 1 The robot gives a part to a machine which then processes it First the robot fetches a part from the In feeder and places it in the machine where the part is processed Then when this has been done the robot takes the part and places it on the Out feeder This work cycle is repeated until the operator stops production 1 2 The main routine The main routine is built up of a number of routine calls which reflect the robot work cycle Routine main Comments fetch_part Fetch part from In feeder leave_machine Leave the part in the machine process_part Start the actual processing fetch_machine Fetch the part leave_part Leave the part on the Out feeder 1 3 Operating the gripper The robot is equipped with a gripper that handles parts A tool tool and its associated tool centre point TCP is defined for this The tool is controlled by a digital output signal defined in the system parameters with the name gripper A high signal indicates that the gripper is holding the part and a low signal indicates that the part has been released User s Guide 17 3 Simple Material Handling Program Examples In addit
469. ssasessesoio sosis eeso essssoi sss 5 7 6 1 Entering text using the teach pendant eseesseeeeeseeseseessreeresresseseresrersessresees 5 9 6 OG OUD i552 i sks batevsnasvosvawevansses eas csvauecsdeasuanedunsuversuaaueevaevsacsswavavvaextesvieousuaeveres 6 1 De GENEPAL EE EE E E E T EA 6 3 1 1 ThE Jogging WANOW vsiaci vessccsvussecasaseeg occas shaves iiiar aiiis esaii iSi 6 3 1 2 Reading the current position seeseeseeeeeeseeseesetesesreesrtsseseresresesrresressesererresse 6 4 1 3 How moving the joystick affects movements sssesseseereesrsereeresserererrreseese 6 4 1 4 Locking OF Joystick ARES irei ees eeen na aaen e EEE EAE Sn Siet 6 5 1 5 Motion Supervisione iiien EE K AE E 6 5 2 Jogging the Robot oesssooesssooecesosccssssossssoocessooeeesosecesssocesssoosessooecssssesesssoossssossse 6 6 2 1 Jogging the robot along one of the base coordinate axes eserereseseree 6 6 2 2 Jogging the robot in the direction of the tool esssseseeeeesesressrrersrresreseee 6 7 2 3 Reorenting the to 3 csisiawaigetaraieegedatana n unn n ss 6 9 2 4 Aligning a tool along a coordinate axis sseeeseeeeeseeeseseeesesrresressrreresresseeere 6 9 2 5 Jogging the robot in the direction of the work object eee eeeeeeeeseeeeeeeees 6 11 2 6 Jogging the robot along one of the world coordinate axes eeseeseeeeesee 6 13 2 1 Usmg stationary toolist raii eiiiai s EE a 6 13 2 8 Jogging the robot axis by axis sss
470. sseossecccosscooesocossocecosscooceooocsocossecccosscooseosessocossecesosscsssesse 10 3 2 Coordinated aX sS seseseesesereceeseserseseresoroesereeoesesoroesesercesesoroeseeeccesosorseseseeoesesorseseee 10 5 Dall Externalaxes generah cenene a e e a A O AaS 10 5 2 2 CE OOUGIN AMON 5322 esisi ous e ea ae a ES ESE es iaaa Esah 10 5 User s Guide 1 6 3 Calibrati n ass sacedcecesscaesasecucencacesseaanenensacnesouesnse suceassonseescnuscaesnneeecapensonscunseuteecnsenie 10 6 Sly Whatiscalbration cues Eene iE E EE atin ee Mace ae os 10 6 3 2 Viewing the calibration status si dsi s2ecadeds5 duct aaaccdegeces axed ech dusedean stuns acBosteosacsanade 10 6 5 2 Checkins the eA Brat Gn 625 ie e a eases 10 7 3 4 Updating revolution COUntErS s iisccsgcdessscgecdeccesd cad sssden ence sedate sessaatoasndeataseseas 10 8 4 Base Frame for the RODOCsccccsssercssvienssespeasescesnsesssespteveessvccdecssnceveccsagesnsebsavenssenen 10 9 4 1 Defining the Base Frame for the Robot uu eeecceeesececsseeeeseeeeenteeeenaeeeenee 10 9 5 Coordinated track Motion csssssesosensccssedensdiesseesvesontsovascusstessonssecsess does enesseutedsnseces 10 12 5 1 How to get started with a coordinated track MOTION eeeeeeeseeeeeteeeeneees 10 12 5 2 Defining the Base Frame for a track MOTION eeeeeeeeeceeeeeceeneeeeeeneeeeaees 10 12 6 Coordinated external axes icc ccouscesscessessnoneedsvensontesnensibens casevecnonsossssasoressansssneogaos 10 16 6 2 Def
471. ssesoossssessossesoseoss 11 6 Sells Restaruno after a StoP iida psy Dov EE EE E EROE aeen 11 7 5 2 Starting a program from the beginning ee eeeeeeeeeceeeseeeeeteeeeneeeenaeeeenes 11 7 6 Shopping th Program sssini essais esines erosia seess ias 11 7 7 Tuning POSICIO y asscbeisscscdecdssondebisdessecssasacdeadsigstecnssesccesasassasesdestesdoseses vesesedsgesssiseness 11 8 8 Operator Dialogs sy scwsesssnsisvccsseuesdeancesecsstensngasvesesacvngeouschstuuhccapevensaovcveesssngeseacvtovaee 11 9 12 Syst m Parameters osc cscs cccceGieclencescwtecdscensccacacessucwcbeccusvessediccasescuseccenens 12 1 1 Changing a Par ae ten svcssivsecsesscsovesessseuvecensssuceessaencecsyves seseneoyecestavenssenveseesonvswavess 12 3 1 1 Subdivision of parameters vi secccsssedecscinvssvedsasoeesdenspaseaveseceeateaveaceesnaeedentpovaavece 12 3 Le Chane ine a parameter 240i acne Ale tee ae Be es tae 12 3 13 DESHI a parameter sedro varseci e a a E a eae deat aE 12 4 ie 7h EANAN TA E A a EEE T E E E E A ee 12 4 1 5 Viewing the last changes that were made seeseseeeeeesesesesresseserrsresrrseresreses 12 5 1 6 Checking Paranieters sii dcstt ies enano aa a BAe Aen 12 5 2 Saving and Loading Parameters ccsssccssssccssssccssscscssccsssssssssscsssecssssessesees 12 6 2 1 Saving parameters to diskette or some other mass storage device 12 6 2 2 Loading parameters from a diskette or some other mass storage device 12 7 3 Topic IO Sign l
472. ssssssesssesesseeessresseesseesseessseessressersseresees 6 14 2 9 Incrementa Movement ccert e e E E aie A 6 14 2 10 Jogging an unsynchronised aXxis seseseseeesseeessressersseeeseressseessessersseessees 6 15 3 J gging External AXES ii sssscccccssssccvessssvdeecssssvdsacessucessnssveccuavavedestens deesssessdasievsesceiut 6 16 3 1 Choosing extertial Units c si cisescaisavenevsacaceasnedasesveunnayoceceusddceloaspesaavelensacdeunneees 6 16 3 2 Jogging external units axis Dy AXIS eee eeeenee cee ceeeeeseeeeseeceaecnseeesneesnees 6 16 1 2 User s Guide 3 3 Jogging external units Coordinated 00 0 ee eesceecesececesececseeeeeseeeeenaeeeeneeeeaae 6 17 7 Inputs and Outputs sscccsesssseoceessssccecesssoccceesssooccsscsscooeecssssoosesesssseceeesso 7 1 RA I E E A E EA A L EE E ET 7 3 1 1 The Inputs Outputs window soyi cicsaseeessecvsaseaeedacasavanseuh had anne vocntawegoasasseccoehicies 7 3 12 NOOSING an W O Tiste 4 r a A a guts dadeac AEA eaen 7 4 1 3 Defining the Most Common VO liSt cceesceeesececesececeecceceeeeeceeeeecsteeeeseeeesaes 7 4 2 Changing Signal Values 55 sesckodsesh cass caves dxvosesvaccosevnccvscenseendscvnccnsdevasavnaeenenspevenscouvens 7 6 2 1 Changing the value of a digital output 0 eee eee ceeeeeeeeeeeeeceeceeeteeeeeneees 7 6 2 2 Changing the value of an analog output signal or a group of output signals 7 6 3 Displaying Information esos vos cesses vcseveasacceeasnecsvaccoskencosgees sesnsscequns
473. st instruction highlighted in Figure 51 2 Then press Paste The window in Figure 52 appears As it is the first instruction in 4 46 User s Guide Basic Operation Changing a Program the program that is highlighted you will be asked where you want the new instruc tion to be inserted MoveL v300 z10 tool0 Insert before No Yes No Cancel OK Figure 52 Dialog box used to insert new instructions when the first instruction is highlighted 3 Select No Press OK 4 The new instruction will be inserted directly under the instruction that was highlighted and will be highlighted itself File Edit View IPL1 IPL2 Program Instr EXERCISE main 2 5 MoveL v300 z10 toold MONEE A SH SOO WAL ceo JLOp MoveL v300 fine tool0 MoveL v300 fine tool0 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 53 An extra position the same as the one copied is added to the program 5 Using the joystick move the robot to the position to which you want it moved 6 Press ModPos see Figure 53 7 Test run the program using continuous execution 8 Select Test gt 9 Push the enabling device 10 Press Start User s Guide 4 47 Changing a Program Basic Operation 13 4 Programming a delay You are now going to program a delay i e make the robot wait a specified amount of time The new instruction will be in
474. start or before pressing Stop or stepping through program Check Make sure conveyor is standing still Move the program pointer 50178 Non optimal movement Non optimal movement Required torque too high Manual adjustment of acceleration or speed is needed Check Reduce acceleration AccSet 50 100 in this movement restore it afterwards AccSet 100 100 Optimize perform ance by search for max acceleration 50 99 Alternatively reduce speed 50180 Corr vector warning Sensor correction vector calculations failed due to previous error 50181 Out of coupled range Joint s and s are out of coupled working range Check Use the joystick to move joints into their coupled working range 50182 Jog in wrong direction Joint s and s are out of coupled working range Check Use the joystick to move joints into their coupled working range 16 84 50183 Robot outside work area The robot has reached the World Zone s Check Check the reason of the World Zone Use the joystick to move the robot out of the World Zone if needed 50184 Corr vector warning Sensor correction vector calculations failed due to previous error 50185 Corr vector warning Sensor correction vector calculations failed due to previous error 50186 Coordination error Not possible to run robot s with coordinated base frame Function not installed in this system Check Install the option Advanced Motion 50187 Coordin
475. stem and press Enter lt e Select the desired parameter and change its value e Press OK to confirm Parameter Description Teach mode max speed Maximum allowed speed in manual mode with reduced speed 7 6 Defining independent motion Independent motion is a part of Advanced Motion and the system has to be loaded in service mode in order to be able to change the independent parameters The control program must be re installed to activate these parameters First select the Query mode When the question Service Standard movement parameters comes up choose Service See the Product Manual Installation and Commissioning For the manipulator only axis 6 can be used in independent mode For external axes there are no limits for independent motion e Choose Topics Manipulator e Choose Types Arm e Select the desired arm and press Enter e Select the desired parameter and change its value User s Guide System Parameters e Press OK to confirm Parameter Description Independent joint Flag used to allow independent mode for this axis For external axes the transmission ratio must be defined as normal with the parameter Transm gear ratio but also with its nominator and denominator values e Choose Types Transmission and specify the following Parameter Description Transm high gear The integer value of the numerator of the transmission gear ratio Only used for independent joints Transm
476. stop The robot stops regardless of which state or mode the system is in immediately when the emergency stop button is pressed The button remains pressed in and to turn to MOTORS ON again must be returned to its original position Duty time counter Indicates the operating time for the manipulator released brakes User s Guide 4 9 System Overview Basic Operation 3 5 Teach pendant The teach pendant is described briefly below see Figure 6 and Figure 7 Enabling ABB device Joystick Display Emergency stop button Figure 6 The teach pendant Emergency stop The robot stops regardless of which state or mode the system is in immediately the emergency stop button is pressed The button remains pressed in and to turn to MOTORS ON again must be returned to its original position Enabling device for safe operation A push button on the teach pendant which when pressed halfway in takes the system to MOTORS ON if the operating mode selector is switched to one of the two manual modes When the enabling device is released or pushed all the way in the robot is taken to the MOTORS OFF state If the enabling device is released and pressed in halfway again within half a second the robot will not return to the MOTORS ON state If this happens the enabling device must first be released and then pushed halfway in again The enabling device should only be activated when the robot is to be moved ei
477. structions by selecting an appropriate instruction in an instruction pick list IPL Although most of these pick lists are fixed some can be user defined This means that you can place the instructions you use most in the same pick list see Defining the Most Common instruction pick list on page 60 The following pick lists are available From the IPLI menu Name Contains Common Some of the most commonly used instructions Prog Flow Instructions that control the program flow Various E g and wait Motion Settings Instructions that affect movements Motion amp Process Motion instructions I O T O instructions Communicate Communication instructions Interrupts Instructions that handle interrupts Error Recovery Instructions that handle errors System amp Time Date and time instructions Mathematics Arithmetic instructions From the IPL2 menu Most Common 1 User defined Most Common 2 User defined Most Common 3 User defined Motion Set Adv Advanced Motion setting instructions Motion Adv Advanced Motion instructions Ext Computer Communication Ware instructions Service Service instructions e Call up one of the instruction pick lists in the IPL1 or IPL2 menu e Call up the instruction pick list that was used most recently by pressing Edit Show IPL If the pick list contains more than 9 instructions you can scroll up down in the list using 9 on the numeric keyboard e Change to the previous or next pick list by
478. system Reload system Replace robot computer board 33210 Feedback Position Error Driver failed to read feedback position on joint f Check Restart system Replace main computer board 33211 Position Control Underrun Unable to complete position control in the allowed time Check Reload system Check noise level on I O connections 33212 DMA Time out Error DMA access failed from main computer to axis computer Check Reload system Replace main computer board and axis computer board User s Guide BaseWare OS 3 1 System and Error Messages 33213 DMA Operation Error DMA Control Operation failed from Main computer to Axis computer Check Reload system Replace main computer board and axis computer board 33214 Float number error Illegal references sent from Main computer to Axis computer for joint f Check Reload system Check system parameters 33220 Axis computer failure Axis computer has returned an error code indicating hardware failure Check Reload system Replace robot computer board 33301 Error in axis computer Check Replace robot computer board 33302 Error in axis computer Axis computer was not able to deactivate VME signal SYSFAIL Check Replace robot computer board 33303 Error in axis computer Axis computer was not able to activate VME signal SYSFAIL Check Replace robot computer board 33304 Error in axis computer Check Replace robot computer board 33305
479. t board 38030 Resolver error Failure in X or Y resolver signal on joint s Sum of squared X and Y exceeds max Check Check resolver and resolver connections Replace measurement boards 38031 Resolver error Failure in X or Y resolver signal on joint s Sum of squared X and Y below min Check Check resolver and resolver connections Replace measurement boards 16 44 38032 Transmission failure Axis computer detected failure in transmission to from serial measurement system d Check Check connections cables for serial measurement system Check shieldings Check for high electromagnetic disturbances along cable run to robot Replace measure board or robot computer 38033 Transmission failure Axis computer detected failure in transmission to from serial measurement system d Check Check connections cables for serial measurement system Check shieldings Check for high electromagnetic disturbances along cable run to robot Replace measure board or robot computer 38034 Transmission failure Axis computer detected failure in transmisson to from serial measurement system d Accumulated errors since warmstart d d absent transmission of d detected Check Check connections cables for serial measurement system Check shieldings Check for high electromagnetic disturbances along cable run to robot Replace measure board or robot computer 38035 Transmission failure Axis computer detected failure in
480. t signal After you have test run the program you will manually open the I O list and look at the signal in question 16 1 Programming an I O instruction 1 Select the Program window see Figure 66 Figure 66 The Program window key The window in Figure 67 appears on the display File Edit View IPL1 IPL2 Program Instr a XXXXX the name 1 6 Movei wa V3 00 A07 EoSere MoveL v300 z10 tool0 Ey you gave the program in Chapter 14 MoveL v300 fine tool0 MoveL v300 fine tool0 WaitTime 3 MoveL v300 fine tool0 Copy Paste OptArg ModPos Test gt Figure 67 The Program Instruction window The new instruction set an output will be entered directly under the highlighted instruction Select the third instruction in the program 2 Select IPL1 IO The window in Figure 68 appears User s Guide 4 57 I O Signals Basic Operation File Edit View IPL1 IPL2 Program Instr EXERCISE main I O 3 6 MoveL v300 z10 tool0 1 InvertDO MoveL v300 z10 tool0 2 PulseDO MoveL v300 fine tool0 3 Reset MoveL v300 fine tool0 4 Set WaitTime 3 MoveL v300 fine tool0 SetA 6 SetDO 7 SetGO 8 WaitDI Copy Paste OptArg ModPos Test gt Figure 68 The pick list including the set instruction Select the function Set in the same way as you selected the WaitTime instruction in Chapter 13 3 After you
481. t the first or the last instruction in the group e Choose Edit Mark e Select the other instructions using ArrowUp O or ArrowDown g The selection will automatically be deactivated when Edit Cut or Edit Copy is chosen You can also make the selection inactive by choosing Edit Unmark To select an argument e Use ArrowRight to move the cursor one argument to the right or ArrowLeft to move the cursor one argument to the left User s Guide Programming and Testing 8 2 Modifying the position in a positioning instruction e Move the robot to the desired position e Select the instruction that is to be changed For instructions containing more than one position e g MoveC select the position argument to be changed e Press the function key ModPos or choose Edit ModPos Note An answer must be given to the password check and confirmation dialog if they have been set to active in the configuration The default set up is no password but with confirmation The maximum movement reorientation of a position can be limited in the system parameters If this has already been implemented the system parameters must be changed in order to allow any greater changes of position See chapter 12 System parameters Topic Teach Pendant The old position is replaced by the current position of the robot This position is related to the current tool and work object Note If anamed position data is modified all other instructions wh
482. tate Command Used to Commutate commutate using the measurement system see the Product Manual Repairs 18 28 User s Guide Quick Reference 7 The System Parameters 7 1 Window System Parameters The System Parameters File Edit Topics Types System Parameters IO Parameter type User signals Parameters Info 1 10 Signal Name dol Unit Name da327_11 Parameters Signal Type DO Signal Number 1 Logical Max 0 000000 Physical Max 0 000000 Logical Min 0 000000 Physical Min 0 000000 Cancel OK 7 1 1 Menu File File 1 Load Saved Parameters 2 Add New Parameters 3 Save All As 4 Save As 5 Check Parameters Restart Command Used to Load Saved Parameters Add New Parameters Save All As Save As Check Parameters Restart User s Guide Parameter topic load parameters from mass storage see page 12 7 add parameters from mass storage see page 12 7 save all parameters on mass storage see page 12 6 save parameters on mass storage see page 12 6 check parameters before restart see page 12 5 restart the robot see page 12 4 18 29 The System Parameters 18 30 7 1 2 Menu Edit 7 1 3 Edit Quick Reference Goto Top Goto Bottom Goto w WN 4 Show Change Log 5 Change Pass Codes Command Goto Top Goto Bottom Goto Show Change Log Change Pass Codes Menu Topics Topics
483. tching trans prot DescriptionReason The transmission protocol s given for application protocol s could not be found Check 1 Change the transmission protocol 71124 Wrong trans prot for NFS DescriptionReason The transmission protocol for the NFS protocol s must be TCP IP Check 1 Change the transmission protocol 71125 Mount Permission denied DescriptionReason Permission was denied to mount the directory s on the server s Check 1 Change the User or Group ID 16 97 System and Error Messages 71126 Directory not exported DescriptionReason Mounting directory s as gt s failed since it is not exported on the server computer s Protocol s Check 1 Export the directory on the server computer 71127 ID s not the equal DescriptionReason The User and Group ID s has to have the same value for all remote disks Check 71128 Ethernet option not inst DescriptionReason The Ethernet Services option has to be installed when remomte mounted disks Check 1 Reboot and install the Ethernet Services option 71129 Too many remote disks DescriptionReason The maximum number of remote mounted disks is d Check 1 Reduces the number of remote mounted disk 71130 Too many remote servers DescriptionReason The maximum number of servers for remote mounted disks is d Check 1 Reduces the number of server
484. tected the write protection must first be removed 13 2 Choosing modules e Choose View Modules The window Program Modules displays all modules present in the program memory see Figure 47 File Edit View Module Program Modules WELDPIPE Name Type 2 4 CAD_POS Program Module Modules gt WELDPIPE Program Module USER System Module BASE System Module New Decl Data gt Figure 47 The Program Modules window displays all modules in the task program e Select the desired module e Press Enter The Program Routines window in which you can choose the desired routine opens User s Guide 8 55 Programming and Testing 8 56 13 3 Creating a new module e Open the window Program Modules by choosing View Modules e Press the function key New A dialog box appears displaying the basic module declaration see Figure 48 The name of the routine is set to moduleN where N is a number incremented each time a routine is created Module definition modulel program module Name Type Cancel OK Figure 48 A module declaration specifies the name and characteristics of a module e Change the name and characteristics of the module by selecting the appropriate field then Press Enter and specify the desired alternative in the dialog box that appears on the display fields marked with C
485. ted If you wish to create data of a type other than that displayed choose View Data Types select the desired data type and press Enter User s Guide Programming and Testing e Select Data New Array A dialog box appears asking for the number of dimensions 1 2 or 3 Make a choice and press Enter A dialog box appears displaying the basic array data declaration see Figure 43 S num Array Data Definition Name reg7 Type variable Global Dimension 5 In Module USER 1 5 1 0 2 0 3 0 4 0 5 0 Cancel OK Figure 43 An array data declaration includes the name and characteristics of the data e Select the appropriate field and specify the desired characteristics by pressing Enter and specifying the desired alternative in the dialog box that appears fields marked with choosing an alternative using the function keys fields marked with 7 specifying the value directly using the numeric keyboard numeric initial value Field Description Name The name of the data a maximum of 16 characters Type Specifies whether the data is to be a constant Const variable Var or persistent variable Pers Global Local Specifies the scope attribute for the data Default for the datatype is set in File Preferences See Default data Global Local on pag
486. ted Powersource Control Unit error Check Request additional information from ESAB ABB 117301 Welding equipment error EPROM checksum error in Wirefeed unit detected at power up Check EPROM in Wirefeed unit is faulty Running with this error gives unpredictable result Exchange EPROM 117302 Welding equipment error Internal RAM read write error in Wirefeed Unit detected at power up Check At least one memory cell in internal microprocessor memory failed in read write test Running with this error gives unpredictable result Replace Wirefeed Unit 117304 Welding equipment error DC supply voltage for 5 Volt regulator in Wirefeed Unit has been down Check Indicates that there is a problem in power supply but the function is probably not affected Check incoming power supply to Wirefeed Unit 117308 Welding equipment error PCB supply voltage 15V on Wirefeed Unit to high or to low Check Replace Wirefeed Unit User s Guide Base Ware OS 3 1 117309 Welding equipment error PCB supply voltage 24V on Wirefeed Unit to high or to low Check Replace Wirefeed Unit 117311 Welding equipment error Long term difference between requested and actual wirefeed velocity Check Hardware problem in wirefeed servo system or voltage drop in 42 V AC supply 117312 Welding equipment error Internal CAN communication failure CAN circuits in Wirefeed Unit is in WARNING state Check Change wirefeed sp
487. tem IO not allowed 20141 Motors Off rejected Motors Off via System IO not allowed 20142 Start rejected Start restart of program via System IO not allowed Check The reason could be that the robot is outside of regain distance 20143 Start main rejected Start of main program via System IO not allowed 20144 Stop rejected Stop of program via System IO not allowed 20145 Stop cycle rejected Stop of program cycle via System IO not allowed 20146 Man interrupt rejected Manual interrupt of program via System IO not allowed 20147 Load and start rejected Load and start of program via System IO not allowed Program file name including mass memory unit to be loaded must be defined 20148 Confirm rejected Emergency Stop Reset Confirm via System IO not allowed 16 30 20149 Error reset rejected Program execution error reset via System IO not allowed 20150 Syncronization rejected Syncronization of mechanical unit via System IO not allowed 20151 Faulty signal name Signal name not possible to subscribe to for Sysio The Signal name might not be in the cfg file for Sysio 20152 Too many restrictions For an action signal in Sysio no restrictions are set The total number of restrictions signals for an action in the cfg file for Sysio are too high 20153 Mot On Start rejected Motors On Start restart of program via System IO not allowed Check The reason could be th
488. ters choose Topics All Topics in the System Parameters window All relevant topics in the robot system will then be displayed Choose the desired topic by selecting it and pressing Enter 1 2 Changing a parameter e Press the Miscellaneous ke to open the System Parameters window y p y e Select System Parameters from the dialog box that appears e Press OK or Enter e Call up the parameter type that contains the parameter to be changed by choosing a topic from the Topics menu and a type from the Types menu All parameters of that type will be displayed as illustrated in Figure 1 To be able to display some parameter types however you must first choose the current unit such as an I O board or a signal by selecting it and pressing Enter User s Guide 12 3 System Parameters 12 4 File Edit Topics Types System Parameters IO Signals Parameter topic Parameter type User signals Parameters Info 1 10 Signal Name dol Unit Name da327_11 Parameters Signal Type DO Signal Number 1 Logical Max 0 000000 Physical Max 0 000000 Logical Min 0 000000 Physical Min 0 000000 OK Figure 1 All parameters of a given type are displayed in the window at the same time e Select the parameter to be changed e Change the value of the parameter by pressing Enter and specifying the desired alternative in the dialog box
489. that the z axis will point downwards User s Guide Programming and Testing Virtual Robot 1 mirror plane Robot 2 wobj1 for robot2 wobj1 mirror pl_m frame x projection of p1 in xy plane Figure 37 Mirroring of a routine using two robots After the work object wobj1 has been defined all programming is done in this frame Then the program is mirrored using the same wobj1 frame as the mirroring frame A position p1 will be mirrored to the new position p1_m After this the mirrored program is moved to robot 2 using the work object wobj1 as described above This means that the mirrored position p1_m will be turned up as if it were mirrored in a virtual mirror plane between the two robots see Figure 37 Mirror function dialogue e Choose View Routines e Select the routine to be mirrored e Choose Special Mirror A dialog box appears see Figure 38 User s Guide 8 43 Programming and Testing Mirroring Of Routine New routine name Work object Mirror frame Mirror axis Routine to mirror left right left_side Car_centre X Cancel OK Figure 38 Mirror function dialogue e Define how the mirroring is to be Field Routine to mirror New routine name Work object Mirror frame key Mirror axis e Start the mirroring with OK 8 44 performed in the fields below Description The name of the routine that will be mirr
490. the brakes are applied and the robot reverts to the MOTORS OFF mode If the enabling device is reactivated the robot changes to the MOTORS ON mode 7 5 Hold to run control 3 8 This function is always active when the operating mode selector is in the MANUAL FULL SPEED position It is possible to set a parameter to make this function active also when the operating mode selector is in the MANUAL position User s Guide Safety When the Hold to run control is active the enabling device and the Hold to run button on the teach pendant must be depressed in order to execute a program When the button is released the axis axes movements stop and the robot remains in the MOTORS ON mode Here is a detailed description of how to execute a program in Hold to run control e Activate the enabling device on the teach pendant e Choose execution mode using the function keys on the teach pendant Start continuous running of the program FWD one instruction forwards BWD one instruction backwards e Wait for the Hold to run alert box e Activate the Hold to run button on the teach pendant Now the program will run with the chosen execution mode as long as the Hold to run button is pressed Releasing the button stops program execution and activating the button will start program execution again For FWD and BWD execution modes the next instruction is run by releasing and activating the Hold to run button It is possible to chan
491. the Product Manual Installation and Commissioning e When a separate transformer and rectifier unit is used to power external axes drive system installed in a separate cabinet read in the configuration files for the transformer and rectifier unit in question User s Guide 12 63 System Parameters Configuration file Identification number EXTAXIS UTIL TRAFO1D2 3HAC 0747 1 or 0749 1 or 0750 1 EXTAXIS UTIL TRAFO2D2 3HAC 0751 1 or 0752 1 or 0753 1 EXTAXIS UTIL TRAFO3D2 3HAC 0754 1 or 0755 1 or 0756 1 EXTAXIS UTIL DCO_D2 DSQC 345A EXTAXIS UTIL DC1_D2 DSQC 345B EXTAXIS UTIL DC2_D2 DSQC 345C EXTAXIS UTIL DC3_D2 DSQC 345D EXTAXIS UTIL DC2T_D2 DSQC 358C The files can be found on the Control Parameters diskette See Loading parameters from a diskette or some other mass storage device on page 7 Use the command File Add new parameters Only one file may be read in for the transformer and rectifier unit respectively even when more than one external axes is used In this way the transformer and rectifier unit will be automatically defined as common to all the external axes in the drive system 2 e Read in the axis configuration files for the required axes EXTAXIS MN_DEF MNxMyDz where x denotes the measurement node number y the measuring system and z the drive system connected The files will be loaded from the Control Parameters diskette See Loading parameters from a diskette or some other mass storage device on page 7 Use the c
492. the base systems are oriented for a specific robot mounting In this case the robot is mounted on the track at an angle of 45 degrees Track base Robot base Robot base Robot base Figure 7 Track and robot base coordinate systems seen from above e Press the Miscellaneous key and select the Service window e Choose View BaseFrame A dialog containing all synchronized mechanical units is shown e Select the track unit and press Enter or Def User s Guide 10 13 Calibration 10 14 A dialog like the one in Figure 8 will appear en Track Base Frame Definition Unit TRACK Method n points n 3 Point Status 1 3 Point 1 Modified Point 2 Point 3 ModPos Cancel OK Figure 8 Track base frame definition dialog To choose definition methods Before you start modifying any positions make sure the desired method is displayed The method defines the number of track positions from where the robot TCP will be moved to the reference point e Select the field Method and press Enter e Choose the number of points to be used for definition and press OK Currently only the three point method is implemented To record world fixed reference points Activate the track unit and run it to the calibration position i e zero position should be displayed on the teach pendant e Select the first point Point 1 e Jog the robot as close as possible to the world fixed tip
493. the command File Save All as in the System parameter window See chapter 12 in this manual e Activate the track unit in the jogging window and check that the coordination is work ing satisfactorily This may be done by choosing World or Wobj in the field Coord and then jogging the track axis The robot TCP should not move but be fixed relative to the object coordinate system 5 2 Defining the Base Frame for a track motion To make coordinated track motion possible it is necessary to define the base frame of the track This frame is located in the calibration position of the track see Figure 6 For the definition of a track base frame you need a world fixed tip within the robot s working range The calibration procedure consists of a number of positionings of the TCP to the reference point Please note that before the base frame of the track may be defined the base frame of the robot must be defined with the track in the calibration position User s Guide Calibration World fixed World tip device Robot base Calibration position for track Figure 6 Track base frame definition procedure The track s base coordinate system has its origin in the robot s base when the track is in its calibration position The x direction is pointing along the linear track path and the z axis of the track s coordinate system is parallel with the z axis of the robot s base coordinate system Figure 7 shows an example of how
494. the program 7 You are now going to manually check the state of the signal 8 Press the Inputs Outputs window key see Figure 72 IS A Previous page Inputs Outputs window key Next page Figure 72 The Manual I O application Browse through the list displayed in the window with the keys as shown in Figure 72 9 Find using the up and down arrow keys the do4 signal in the IO list and highlight it 10 Check its value You can change the value using the function keys 0 Z that appear on the display each time an output signal is highlighted 11 Change the value of the signal and then press the Prog application key 12 Test run the program once more Test and check the value of the signal again INFORMATION When you use lists from the View menu in the Manual I O window you can choose to have only input signals only output signals etc shown on the display User s Guide 4 59 I O Signals Basic Operation 4 60 User s Guide Starting up CONTENTS Page 1 Switching on the Power Supplly csccsssccsssssssssscsssssssscscssssccssssecsessscssscsssesscsees 3 l 1 Errors On start Uphaar a eee eae iat eee 4 2 The Operators Painel sicecsicckcdesseschucckevtcccecavecsewcnedeasevecsasveaneeckucsesacateuvesucvesanvaceereaene 4 3 Selecting the Operating Mode sessesssesesecesooesoocessecssccssocescosssocssscessocesocessosesssessse 4 3 1 Automatic mode production mode
495. the program will be executed once and then will stop in position 4 one cycle Select Continuous execution again User s Guide Basic Operation Stopping the Program 9 Stopping the Program Stop the program by pressing the Stop key on the teach pendant see Figure 40 AA ED ED FRIDED PY Figure 40 Stop key on the teach pendant User s Guide 4 35 Stopping the Program Basic Operation 4 36 User s Guide Basic Operation Automatic Mode 10 Automatic Mode Automatic mode is used to execute ready made programs 1 Turn the operating mode selector on the operator s panel to position The window in Figure 41 appears N Change of Operating Mode Operating Mode has been changed from MANUAL to AUTO Please acknowledge this by pressing OK If Cancel the Operating Mode Selector must be switched back to MANUAL Cancel OK Figure 41 Dialog box used to confirm a change from manual to automatic mode 2 Press OK You have now changed to automatic mode and the Production window appears on the display see Figure 42 File Edit View Window title Production Info CAR_LIN1 Program name Routine main Routine name Robot Status Stopped Program status velocity Speed 75 lt ____ Adjusted velocity Running mode Continuous lt i gt Running mode 2 39 Program MoveL pl v500 220 tooll gt MoveL p2 v500 220
496. the robot as close as possible to the elongator point on the positive Z axis e Modify the position by pressing the function key ModPos To calculate the robot base frame e Press OK to calculate the robot base frame for the selected mechanical unit When the calculation is finished a dialog like the one in Figure 5 will appear E Robot Base Frame Calculation Result Unit Calculation Log MASTER_ROBOT 1 10 Method n points n 4 Mean error 1 12 Max error 2 31 Cartesian X 10 34 Cartesian Y 234 56 Cartesian Z 78 56 File Cancel OK Figure 5 The result of a robot base frame calculation Field Unit List contents Method Mean error Max error Cartesian X Cartesian Y Cartesian Z Quaternion 1 4 Description The name of the mechanical unit for which the definition of robot base frame is to be done Description Displays the selected calibration method The accuracy of the robot positioning against the tip The maximun error for one positioning The x coordinate for the base frame The y coordinate for the base frame The z coordinate for the base frame Orientation components for the base frame The result of the calculation is expressed in the world coordinate system The calculation result can be saved in a separate file for later use in a PC Press the function key File e Specify a name and a location where to save the result e Choose OK to confirm the sav
497. ther with the joystick or during program execution Joystick The joystick is used to jog move the robot manually e g when programming the robot Display Used to display all information during programming to change programs etc It can accommodate 16 lines each line can accommodate 40 characters 4 10 User s Guide Basic Operation System Overview Figure 7 shows the names of the various keys on the teach pendant Menu keys Contrast Display __ _ _ ABD Jogging __ Numeric Program Keypad Window Inputs a Delete Misc Enter User defined key Stop key Function keys Mee defined Navigation keys Figure 7 An overview of the various keys on the teach pendant Version 2 Window keys to select a window to work with on the display mY Jogging Used to jog the robot Program Used to program and test UF i Inputs Outputs Used to manually operate the input and output signals connected to the robot T Misc Miscellaneous other windows i e the System Parameters Service Production and File Manager windows User s Guide System Overview Basic Operation Navigation keys to move the cursor within a window on the display List Press to move the cursor from one part of the window to J another normally separated by a double line n Previous Next page Press to see the next previous page
498. tion error in s Check This is probably an off line generated dummy position undefined orienta tion that needs to be MODPOS 40715 IOEnable call interrupted Task s Call to I O unit AOs was inerrupted Check IOEnable or IODisable have been exec from an other task Make a retry 40720 Alias IO installation The task s could not refresh all alias IO 40721 IO installation The task s could not refresh all IO as RAPID symbols Check Check the IO configuration 40722 Mechanical units The task s could not refresh all mechanical units as RAPID symbols Check Check the Motion configuration 40900 Discr App System Error s 40901 Discr App Sys Message WARNING A new application or proc ess has been ordered A warm start is required to install a new configuration 16 76 40902 Discrete Application Task s Error from 16s Can t find the process 16s Check Check the installed process es Motion error messages 50001 Serious motion error Not possible to proceed motion control Check Start up the system again 50021 Joint position error Actual position of joint s is too far away from the ordered position Check Check trim parameters external forces or hardware 50022 Too low DC link voltage Check Check voltage from Motor On contactors Replace DC link 50023 Stop Restart error The stop was made when too many move instructions were queued for
499. tion key until the cor rect unit is displayed To store on a diskette choose flp1 e Specify the file name by selecting the field Name and pressing Enter Enter the desired name and press OK to confirm e Select the directory to which the parameters are to be saved You can move to the next directory level by selecting the desired directory or upwards and pressing Enter e Choose OK to confirm the save 2 2 Loading parameters from a diskette or some other mass storage device Parameters can be loaded in their entirety or loaded as individual parameter topics If several parameters are to be loaded the parameters must be placed in a directory e Choose File Load Saved Parameters to replace a complete parameter topic e Choose File Add New Parameters to add new parameters to the current one e g when defining an external axis e Choose File Add or Replace Parameters to replace parts of a parameter topic e g when reediting an external axis If a parameter already exists its value will be updated according to the new one If the parameter does not exist it will be added A dialog box appears displaying all parameters in the current directory see Figure 4 Load Parameters 7 Select a directory or a file to Open Saved or New ee Massmemory Unit flp1 PARAM Mass storage unit Directory level 1 2 sof Go up 1 level BACKW18 Directo
500. tion settings for jogging and the current position of the robot See the example in Figure 2 User s Guide 6 3 Jogging Special Jogging Robot pos Unit Robot xX 1234 5 Motion Linear y 244 9 Current z 12 8 aa n C t Q1 0 7071 positio urren e Coord Base Q2 0 0000 motion Tool tool0 Q3 0 0000 settings Wobj wobj0 Q4 0 7071 Motion Joystick lock None xz y resulting from Incremental No 19 gt different deflections of World Base Tool Wobj the joystick Figure 2 Define the various jogging settings in the Jogging window 1 2 Reading the current position The current position of the robot is displayed in the Jogging window see Figure 2 In Linear or Reorientation motion types the position and orientation of the tool in relation to the coordinate system of the chosen work object is displayed regardless of the type of coordinate system used In Axis by Axis motion type with Robot as the unit the positions of the robot axes are displayed in degrees related to the calibration position of the respective axis When an external unit is moved the position of the axes is displayed In the case of linear axes the position is displayed in mm related to the calibration position For rotating axes the position is displayed in degrees related to the calibration position When a unit is unsynchronised no position is displayed 1 3 How moving the joystick affect
501. tionings of the turntable turntable seen from above 0 degrees rotation 45 degrees rotation Figure 11 The user coordinate system at various angles of rotation User s Guide 10 17 Calibration 10 18 e Press the Miscellaneous key and select the Service window e Choose View BaseFrame A dialog containing all synchronized mechanical units is shown e Select the mechanical unit and press Enter or Def A dialog like the one in Figure 12 will appear Sra Rot Single User Frame Definition Unit ROT_SINGLE Method n points n 4 Point Status 1 3 Point 1 Modified Point 2 Point 3 ModPos Cancel OK Figure 12 Dialog for definition of user frame for a rotational axis To choose a definition method Before you start modifying any positions make sure the desired method is displayed e Select the field Method and press Enter e Choose number of points to use for definition and press OK Currently only the four point method is implemented To record turntable reference points Activate the mechanical unit and run it to its calibration position i e zero position should be displayed on the teach pendant e Select the first point Point 1 e Point out the reference point on the turntable with the robot s TCP e Modify the position by pressing the function key ModPos e Rotate the turntable in the positive direction and repeat the above for the points Point 2
502. tivated e g by choosing the unit in the Jogging window the output signal is automatically set A check is made later that the corresponding input signal from the relay is set e Define the input and output signals for the relays See Defining input and output signals on page 12 Restart the robot using File Restart and check that the external axes can be activated from the I O window e Read in a relay configuration file EXTAXIS UTIL RELAY from the Control Parameters diskette See Loading parameters from a diskette or some other mass storage device on page 7 Use the command File Add new parameters A new relay with the name RELAY _x will now be created e Choose Area Manipulator e Choose Types Relays and specify the name of the relay and its signal connections User s Guide System Parameters Parameter Description Name Name of the relay e g relay_track max 16 characters This must be changed when more relays are to be used Out signal Denotes the logical name of the output signal to the relay The name must be identical including upper and lower case letters to the name used for the signal definition In signal Denotes the logical name of the input signal to the relay The name must be identical including upper and lower case letters to the name used for the signal definition Inverted input Denotes whether or not an inverted input is to be used to the relay e Choose Types Mechanical unit and specify und
503. tive to the next point Positive X e Modify the position by pressing the function key ModPos e Select the point Positive X e Point out the reference point on the positive x axis with the robot s TCP e Modify the position by pressing the function key ModPos e Select the point Positive Y e Point out the reference point on the positive y axis with the robot s TCP e Modify the position by pressing the function key ModPos To calculate the user frame e Press OK to calculate the user frame for the selected mechanical unit When the calculation is finished a dialog like the one in Figure 16 will appear The calculation log shows the user frame expressed in the world coordinate system when the mechanical unit is in its calibration position User s Guide 10 21 Calibration SaaS Orbit User Frame Calculation Result Unit ORBIT Calculation Log 1 9 Cartesian X 123 45 Cartesian Y 45 67 Cartesian Z 398 56 Quaternion 1 0 382683 Quaternion 2 0 000000 Quaternion 3 0 923880 File Cancel OK Figure 16 The result of a linear moving base frame calculation Field Description Unit The name of the mechanical unit for which the definition of user frame is to be done List contents Description Cartesian X The x coordinate for the user frame Cartesian Y The y coordinate for the user frame Cartesian Z The z coordinate for the user frame Quaternion 1 4 Orientation components for the u
504. to MoveJ Choose Edit Search in the Program Test or Program Instr window A dialog box appears see Figure 32 p Search amp Replace Mod All Rout All Direction Forward Search do2 Replace do3 weldpipe main MoveL pl1 v100 z10 tool0 Set dol Reset do2 WaitTime 2 1 4 All Mod OK Figure 32 The search and replace dialog User s Guide 8 37 Programming and Testing e Define how the search is to be carried out by defining the following fields Field Description Mod If All modules is selected the current module name is shown to the right of the field If Mod or Enter J are pressed a list of available modules is shown and a specific module can be selected Rout Searching replacing is performed in all available routines in the module selected from the module field If Rout or Enter are pressed a list of available routines is shown and a specific routine can be selected Direction Directions for searching Search Selection field where a list of available names to search for is shown when you press Enter lt Replace Selection field where a list of available names to replace is shown when you press Enter To start a search e Move the cursor to the lower part of the window using the list key 33 see Figure Search amp Replace
505. to the object frame related to the user frame related to the world frame Both object and user frames are included in a work object which may be added to each move instruction See Figure 31 Object coordinate system User coordinate system Figure 31 A user and an object coordinate system describe the position of a work object The intention is to use the work object to define both the position of a table user frame and the position of the object to work on object frame When the table or the object is moved the program may still work if the corresponding work object is updated These coordinate systems are very well suited to off line programming since the posi tions specified can usually be taken directly from a drawing of the work object The program displacement coordinate system is used for small temporary displace ments e g as the result of a search operation This displacement is modal i e it is acti vated in a separate instruction and then it remains active until it is deactivated in another separate instruction See Figure 32 Figure 32 Using a displacement frame all positions in the program can be displaced All such program displacements include both robot displacements and external axes displacements Please note the difference between work object and program displacement The work object used must be added to each move instruction and it must be active when pro gramming the move instruction It sh
506. tomatically A sequence of data and associated operands e g reg 5 or regl gt 5 A point which the robot only passes in the vicinity of without stopping The distance to that point depends on the size of the programmed zone A routine that returns a value A number of digital signals that are grouped together and handled as one signal An event that temporarily interrupts program execution and executes a trap routine Electrical inputs and outputs The routine that usually starts when the Start key is pressed The applicable mode when the operating mode switch is set to A A group of external axes A group of routines and data i e a part of the program The state of the robot i e whether or not the power supply to the motors is switched on The panel located on the front of the control system The direction of an end effector for example The input data of a routine sent with the routine call It cor responds to the argument of an instruction A variable the value of which is persistent A routine which when called can independently form an instruction 20 7 Glossary Program Program data Program module Record Routine Routine data Start point Stop point System module System parameters The set of instructions and data which define the task of the robot Programs do not however contain system modules Data that can be accessed in a complete module or in the complete program
507. tre z X arm 1 Figure 27 The arm coordinate system for axes 1 2 and 3 Now this arm load must be connected to the current arm axis e Choose Types Arm e Select the desired arm and press Enter e Select the parameter Use customer arm load and specify the name of the arm load previously defined Press OK to confirm 7 8 Defining arm check point If an extra load such as a transformer or a welding bar roller is attached to an arm then a point on this equipment can be defined In this case the robot monitors the speed of that point so that it does not exceed 250 mm s in the manual operating mode reduced speed e Choose Topics Manipulator e Choose Types Arm check point e Select the desired parameter and change its value Press OK to confirm User s Guide System Parameters Parameter Description Name The name of the check point e g chk_pnt_1 max 16 characters Position x The position of the check point specified on the basis of the Position y current coordinate system of the arm in meters See the Position z example in Figure 28 Z arm 3 Check point Figure 28 Definition of the check point for arm 3 Now this check point must be connected to the current arm axis e Choose Types Arm e Select the desired axis and press Enter e Select the parameter Use check point and specify the name of the arm check point previously defined Press OK t
508. ty this is described in Chapter 19 Special Functionality in this Robot To make things easier to locate and understand Chapter 20 contains an index and a glossary 3 1 Typographic conventions The commands located under any of the five menu keys at the top of the teach pen dant display are written in the form of Menu Command For example to activate the Print command in the File menu you choose File Print The names on the function keys and in the entry fields are specified in bold italic typeface e g Modpos Words belonging to the actual programming language such as instruction names are written in italics e g MoveL Examples of programs are always displayed in the same way as they are output to diskette or a printer This differs from what is displayed on the teach pendant in the following ways Certain control words that are masked in the teach pendant display are printed e g words indicating the start and end of a routine Data and routine declarations are printed in the formal form e g VAR num reg User s Guide Introduction 4 Reader s Comments You can use the next page to send us your comments about the manual In this way you will help us to improve the manual and make it easier for yourself to follow in the future Thank you kindly for your cooperation User s Guide 2 5 Introduction 2 6 User s Guide CONTENTS Page De GMO T Al EEA E AS ETAETA ATE EEEE EE 3 t l Introd OW Scie oki
509. uence of several TriggX that controls the speed proportional AO signal 40659 Undefined load WARNING Argument 16s has undefined load mass equal to 0 kg IMPORTANT TO DEFINE CORRECT LOAD to avoid mechanical damages of the robot and to get good motion performance Check Define the actual load for the tool or the grip load before program movement or jogging User s Guide BaseWare OS 3 1 System and Error Messages 40660 Undefined load WARNING Argument 16s has undefined load centre of gravity IMPORTANT TO DEFINE CORRECT LOAD to avoid mechanical damages of the robot and to get good motion performance Check Define the actual centre of gravity for the tool load or the grip load before program movement or jogging cog x cog y and cog z can not be 0 mm at the same time 40661 Search error The signal 16s for the SearchX instruction is already high at the start of searching 40662 Invalid worldzone type The switch 16s must be associated with a 16s worldzone Check If use of switch Temp the datatype must be wztemporary in WorldZone If use of switch Stat the datatype must be wzstationary in WorldZone 40663 World zone not in use The 16s argument of the instruction 16s must refer to a worldzone that has been defined and activated by a WZLimSup or WZDOSet instruction 40664 World zone already in use The 16s worldzone has already been defined and activated
510. un at the highest level with no other task that could suspend its execution The name of the start routine It should be a RAPID routine without any parameters and reachable in this task only valid for STATIC and SEMISTATIC tasks This parameter should be set to NO if the system is to accept unsolved references in the program while linking a module or otherwise set to YES default value is YES The parameter must be set to NO if the instructions Load Erase are to be used There will be a runtime error on execution of an unresolved reference TrustLevel handle the system behaviour when a SEMISTATIC or STATIC task is stopped for some reason or not executable SysFail This is the default behaviour All NORMAL tasks normally only the MAIN task will be stopped Besides that the system is set to state SYS_FAIL All jogging and program start orders will be rejected Only a new warm start resets the system This should be used when the task has some security supervisions SysHalt All NORMAL tasks will be stopped The system is forced to motors off When taking up the system to motors on it is possible to jog the robot but a new attempt to start the program will be rejected A new warm start will reset the system SysStop All NORMAL tasks will be stopped but is restartable Jogging is also possible NoSafety Only the actual task itself will stop If a task is specified as a STATIC or SEMISTATIC type all modules must
511. uous Check At least one other object sharing the same name as the referred data is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 16 56 40070 Reference error Task 16s Function reference 16s is ambiguous Check At least one other object sharing the same name as the referred function is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40071 Reference error Task 16s Label reference 16s is ambiguous Check At least one other object sharing the same name as the referred label is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40072 Reference error Task 16s Procedure reference 16s is ambiguous Check At least one other object sharing the same name as the referred procedure is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40073 Reference error Task 16s Trap reference 16s is ambiguous Check At least one other object sharing the same name as the referred trap is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40074 Reference error Task 16s 16s not entire data reference Check The specified name identifies an object other than data Check i
512. ut is selected its status can be changed using the function keys User s Guide 4 17 Working with Windows Basic Operation 3 You can select a signal in the list move the cursor in several ways Movement Select One line up ArrowUp a One line down ArrowDown UJ To the first line in the list Goto top from the Edit menu To the last line in the list Goto bottom from the Edit menu To the next page NextPage W To the previous page PreviousPage A To select a specific line in the list Goto from the Edit menu enter the desired line number and press OK 4 Windows are sometimes divided in two by a double line see Figure 12 5 When an output is selected two function keys will be displayed see Figure 12 File Edit View Inputs Outputs All signals double line Value ra Name dil di2 epeo grip2 grip3 grip4 progno welderror orrrroor iw 6 0 l Function keys Figure 12 A window with two parts In some windows you can move the cursor between the different parts of the window In these windows move the cursor using the List key 4 18 User s Guide Basic Operation Working with Windows 6 There are four window keys on the teach pendant see Figure 13 below and Chapter 3 AA ED ED PADI Window keys Figure 13 The four window keys When you press a window key the active window will be hidden under the new one Each time you select a wi
513. uter board 37033 Main computer error Check Replace main computer board User s Guide Base Ware OS 3 1 37034 Main computer error Check Replace main computer board 37035 Main computer error Check Replace main computer board 37036 Main computer error Check Replace main computer board 37037 Main computer error Check Replace main computer board 37038 Main computer error Check Replace main computer board 37039 Main computer error Check Replace main computer board 37040 Main computer error Check Replace main computer board 37041 Main computer error Check Replace main computer board 37042 Main computer error Check Replace main computer board 37043 Main computer error Check Replace main computer board 37044 Main computer error Check Replace main computer board 37045 Main computer error Check Replace main computer board 37046 Main computer error Check Replace main computer board User s Guide BaseWare OS 3 1 System and Error Messages 37047 Main computer error Check Replace main computer board 37048 Main computer error Check Replace main computer board 37049 Contactor activate Error Contactor for station s or Supervisory contactor or auxiliary contactor did not activate or energize Check Restart system Check contactor or Supervisory contactor or auxiliary contactor Check digital output to contactor or digital input from contactor Replace system boa
514. utine Program data must have names that are unique within the module Rename the data or change the conflicting name 40040 Name error Task 16s Global constant name 16s ambiguous Check Global data must have names that are unique among all the global types data global routines and modules in the entire program Rename the data or change the conflicting name User s Guide BaseWare OS 3 1 System and Error Messages 40041 Name error Task 16s Global persistent name 16s ambiguous Check Global data must have names that are unique among all the global types data global routines and modules in the entire program Rename the data or change the conflicting name 40042 Name error Task 16s Global routine name 16s ambiguous Check Global routines must have names that are unique among all the global types data global routines and modules in the entire program Rename the routine or change the conflicting name 40043 Name error Task 16s Global variable name 16s ambiguous Check Global data must have names that are unique among all the global types data global routines and modules in the entire program Rename the data or change the conflicting name 40044 Name error Task 16s Label name 16s ambiguous Check Labels must have names that are unique within the routine Rename the label or change the conflicting name 40045 Name error Task 16s Module name 16
515. utput instruction contains the following information information on the output to be changed information on the desired value User s Guide 9 7 The programming language RAPID Digital output Reset dol Output Desired value SetDO dol high e Call up the instruction pick list for I O instructions by choosing IPL1 IO e Choose the desired instruction by pressing the appropriate numeric key You must now specify the output to be changed All the different robot outputs are displayed for this purpose see Figure 8 Instruction Argument Reset lt EXP gt Signal 1 4 New dol do2 do3 do4 do5 do6 do7 do8 do9 do10 do11 Next Func More Cancel OK Figure 8 The dialog box used to define an output e Select the desired output e Choose OK to confirm 3 Waiting 3 1 Wating for an input A wait until input instruction contains the following information the name of the input the input value necessary for program execution to continue 9 8 User s Guide The programming language RAPID Input Value f WaitDI dil 1 Input Value WaitUntil dil 1 The WaitUntil instruction can also be used to wait for several inputs e Choose IPL1 Various e Select the instruction WaitDI You must now specify the condition that must be satisfied before the program execution is to continue You do this using the dialog box illustrated in Figure 9
516. vccaskencsuginececi anena toison rs osoei sssini 6 2 1 Jogging the robot along one of the base coordinate axes eseeeeeseseerreeerereereeee 6 2 2 Jogging the robot in the direction of the tool sssssssesessessesrrssrssresresseserssressessess 7 23 Reornentins the toole ii EEE E E E ae Mune el EE a Ree tee 9 2 4 Aligning a tool along a coordinate axis eeseeeeeeseeseeseessesreeseesrrsrrssressrseresressesee 9 2 5 Jogging the robot in the direction of the work object esesesesseseserereeresesrse 11 2 6 Jogging the robot along one of the world coordinate axes eeeseeeseereeeeeereeeeee 13 Zid Using a stationary COO gist cicada a pen a e s A A TE 13 2 8 Jogging the robot axis by axis s sssesssessesssesessetssseessresseesseeesseeesseesseesseesseeessees 14 2 9 Incrementa Mmoyement a r e aea as ae E aa e EPRE ESE ERES 14 2 10 Jogging an unsynchronised axis cessceesseceencecesseeceeneeceseeeceeneeceeeeecseeeesteeeesaes 15 3 Jogging External Axes 5 csssived scutes scenceessasevisivaasnabesccenverssdenetenssnecaeageveudabcasscessadenesenasasseostun 16 Dall Choosing exterial UNS esnie e a a a E N nia 16 3 2 Jogging external units axis by aXxis esessseesesseesressessersresreesersrsrresressrseresressesee 16 3 3 Jogging external units coordinated eseseseeseeseeesesreesersresrisseesresersseessrseresressesee 17 User s Guide 6 1 Jogging 6 2 User s Guide Jogging Jogging 1 General A
517. ve and to block operation from a computer link or remote control panel e The robot s speed is limited to max 250 mm s 10 inches s when the operating mode selector is in position lt 250 mm s This should be the normal position when entering the working space The position 100 full speed may only be used by trained per sonnel who are aware of the risks that this entails Do not change Transm gear ratio or other kinematic parameters from the teach pendant or a PC This will affect the safety function Reduced speed 250 mm s e During programming and testing the enabling device must be released as soon as there is no need for the robot to move The enabling device must never be rendered inoperative in any way e The programmer must always take the teach pendant with him her when entering through the safety gate to the robot s working space so that no one else can take over control of the robot without his her knowledge User s Guide 3 5 Safety 7 Safety Functions 7 1 The safety control chain of operation The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode MOTORS ON mode means that drive power is supplied to the motors If any contact in the safety ch
518. vements e If the axis moves for both movements the axis is too stiff and the minimum factor should be reduced If the axis does not move for any movement the axis is too soft and the minimum factor should be increased e Repeat the last two actions until the axis does not move for the smaller movement but does move for the bigger movement The movements in the trim procedure should be done close to the point where the soft servo is activated to minimize the risk of the axis collapsing Kp Kv ratio factor determines the stability margin for the axis A value less than 1 0 increases the stability It not possible to set this parameter to a value larger than 1 0 since the stability of the axis would be jeopardized If Ramp time is changed the duration of the activation and deactivation phase will change A short ramp time can result in snatch of the axis at activation 7 19 Defining the joystick directions for the robot and external manipulator These values are available under the System Parameters window e Load the jog direction templates file for the mechanical units See Loading parameters from a diskette or some other mass storage device on page 7 Use the command File Add New parameters The jog direction template files can be found on the CONTROLLER PARAMETER diskette under directory JOGDIR File ROBOT_M CFG is intended for the robot Loading this file will define the parameter instance name strings linear_jog_m re
519. w Data e Choose Data In Module To list all program data in all modules again choose Data In System 13 10 Duplicating data from one module to another Data can be duplicated from one module to another Routine data cannot however be duplicated e Choose the module in which the new data is to be included e Select the data to be duplicated in the Program Data window e Continue in the normal way as described in Duplicating data on page 50 13 11 Saving modules on diskette or some other type of mass memory To save a module that has been stored previously e Open the window Program Modules by choosing View Modules e Select the module to be saved e Choose File Save Module The module is duplicated to mass memory and replaces the last version saved User s Guide Programming and Testing To save under a new name e Open the window Program Modules by choosing View Modules e Select the module to be saved e Choose File Save Module As A dialog box appears displaying all modules and programs in the current directory see Figure 50 EMN Save Module Name Cadpos Mass memory unit Massmemory unit flpl MODULES x 10 Directory level gs Go up 1 level CAD_POS Program Module SYSTEM1 System Module SYSTEM2 System Module Unit New Dir Cancel OK Figure 50 The dialog box used to store modules e If necessary change the mass memory unit by pressing Unit until the correct unit
520. window e Choose View Calibration e Select the desired unit e Move the robot or the chosen unit close to half a motor revolution at the furthest the calibration pose The latter is usually indicated by a scribed line or a vernier scale The calibration pose of the robot is described in the chapter on Installation and Commissioning in the Product Manual e Choose Calib Rev Counter Update A dialog box will appear in which you can choose the axis you want to update see Figure 2 Rev Counter Updating Robot To update include axes and press OK Axis Status 4 6 Not Rev Counter updated Not Rev Counter updated Calibrated Calibrated Not Rev Counter updated Not Rev Counter updated Incl All Cancel OK OuBRWNHE Figure 2 The dialog box used to select axes when updating the revolution counter e Select the axis to be updated and press the Incl function key An x to the left indicates that the axis is to be updated e Use the same procedure on the remaining axes or press the function key All which selects all axes A selected axis can be deselected by pressing the Excl function key e Confirm the choice of axes by pressing OK e Start updating by pressing OK in the confirmation dialog box 10 8 User s Guide 4 Base Frame for the Robot 4 1 Defining the Base Frame for the Robot Calibration The following methods are used to define the location of the robot s base frame in rela tio
521. x error 6 73 Quaternion 1 0 345271 File Cancel OK Figure 38 The result after a displacement frame calculation User s Guide 10 45 Calibration Field Description Orig The origin of the displacement frame Mean Error The average distance that the points are from the original points i e how accurately the robot was positioned Max Error The maximum error for one point The calculation result can be saved in a separate file for later use in a PC Note however that this file cannot be read by the robot e Press the function key File e Specify a name and a place to save the result e Choose OK to confirm the save e If the estimated error is acceptable press OK to confirm the new displacement frame not acceptable redefine by pressing Cancel 10 46 User s Guide Production Running CONTENTS Page The Production WIN OW sesiscacecsecssicsasasssacecendssaedendiscusnsosccondassssnussbudesdebstuedniacmedveroncneuases Reading a Program sssi ecu cules Uh cava ce nscconaseeaacyouse cxveueeucaesseunexo eo wiea vse nenans erences epee Changing the Override Speed sssscsscssssssssssssssssssscssscsssssscsssssesssssessssesssasesssasereees Changing the Program Running Mod e ccssccssscccssssscssscccsssccsssccsssscssssssssssecsesesees an Aa U Nme ANAA U Starting th Pr AMMR gcc cc sda cc caida ce ees da cocens snes dees soso pessoacorase siess oss dosao ss sohe sos depoa visor sasos 5
522. xis Four positionings of the robot s TCP on the reference point are performed with the second axis rotated to different angles This frame coincides with the user frame when both axes are fixed to their calibration positions To choose a definition method Before you start modifying any positions make sure the desired method is displayed and the mechanical unit is activated e Select the field Method and press Enter e Choose the number of points to use for the axis definition and press OK To choose axis You can choose which one of the axes you want to define Remember that both axes must be defined to complete the user frame definition It is possible to redefine both axes or just one of them e Select the field Axis and press Enter to switch axis User s Guide 10 25 Calibration To record reference points for the first axis definition Make sure Axis 1 is chosen Run the mechanical unit to its calibration position e Select the first point Point 1 e Point out the reference point on the turntable with the robot s TCP e Modify the position by pressing the function key ModPos e Rotate the first axis to a greater angle and repeat the above for the points Point 2 to Point n e Press OK to calculate the frame of the first axis To record reference points for the second axis definition Make sure Axis 2 is chosen Run the mechanical unit to its calibration position e Select the first p
523. y axis movement by setting the motion keys see Figure 21 Axes 1 2 3 dis r uF ei i Axes 4 5 6 Figure 21 Specify the axes you want to move by setting the keys as above Only the axis affected by the joystick deflection moves which means that the TCP does not move linearly 2 9 Incremental movement Incremental movement is used to adjust the position of the robot exactly This means that each time the joystick is moved the robot moves one step increment If the joystick is deflected for one or more seconds a sequence of steps at a rate of 10 steps per second will be generated as long as the joystick is deflected e Select the field Incremental see Figure 22 fal __ oJ 5 rontdooxr Q4 0 7071 Joystick lock None 231 Incremental No w9 gt No Small Medium Large User Figure 22 Specify the incremental step size in the field Incremental 6 14 User s Guide Jogging e Specify the size of the steps using the function keys No Normal continuous movement Small Approx 0 05 mm or 0 005 degrees per joystick deflection Medium Approx 1 mm or 0 02 degrees per joystick deflection Large Approx 5 mm or 0 2 degrees per joystick deflection User User defined increments You can also use the key on the teach pendant to turn incremental movement on and off If you want to specify the sizes of the user def
524. ype pose and press Enter e Select the displacement to be changed and press Enter e Select the frame component x y z q1 q4 that you wish to change e Change the value using the numeric keyboard To enter a decimal point and minus use the function keys e Choose OK to confirm the change User s Guide 10 43 Calibration 10 44 8 13 Methods for defining a displacement frame The following method is supported n point At least three well defined points on an object at its initial position and the same points when the object is in its new position see Figure 36 are used to define the displacement frame Pl P3 te aia Figure 36 A displacement frame can be defined by moving the robot to a number of points 8 14 Using the robot to change a displacement frame e Open the Program Data Types window by choosing View Data Types e Select the type pose and press Enter e Select the displacement frame to be defined or create a new one see Creating a new displacement frame on page 43 e Choose Special Define Coord A dialog box appears displaying the points defined by the method that was used see Figure 37 Displacement Frame Definition Disp disp4 Method n points n 3 Point Status 1 6 Initial Point 1 Modified Initial Point 2 Modified Initial Point 3 Moved Point 1 Desc ModPos Cancel OK Figur
525. ype tooldata and press Enter lt e Select the tool to be changed and press Enter lt e Select the TCP component x y z that you wish to change e Change the value using the numeric keyboard To enter a decimal point or minus sign use the function keys e Select the mass component e Change the weight using the numeric keyboard e If the tool is stationary i e not mounted on the robot change the component robhold to FALSE For more information about stationary tools see Stationary tool on page 33 e Choose OK to confirm the change Note Only the mass of the tool should be specified A payload handled by a gripper is specified by the instruction GripLoad 7 3 Methods of defining the tool coordinate system To define the TCP of a tool you need a world fixed tip within the robot s working space You then jog to at least four robot positions with different orientations as close as possible to the world fixed tip see Figure 24 These positions are called approach points G TANK World fixed tip Figure 24 Approach points for a tool s TCP To define a complete orientation of a tool you move any position on the desired z axis and any position on the desired x axis to the world fixed tip These positions are called elongator points see Figure 25 This can be done by fitting an elongator to the tool to define the z and x directions or by aligning the tool according to the wor
526. ystem Parameters rotating_move if rotating axes excluded otherwise e Under ARM_TYPE e For each arm of the external robot in question length a according to Craigh s definition offset_x 0 offset_y 0 theta_home_position theta according to Craigh s definition offset_z d according to Craigh s definition attitude alpha according to Craigh s definition Structures with less than 6 axes require a LOCKED definition for all references to the inactive axes 7 22 Servo parameters Adjustment of the servo to control slow external equipment and the use of brakes when the robot is waiting for movement Event preset time Event preset time is used to delay the robot to make it possible to activate control external equipment up to 0 5 seconds before the robot runs through the position Up to about 70 ms there is no need to adjust Event preset time when the servo has an internal lag But if a longer adjustment is needed then set Event preset time to the longest time wanted Example the parameter EquipLag in the TriggEquip is set to 200 ms below If this is the longest time set Event preset time to 200 ms TriggEquip gunon 10 0 2 Op gun 1 TriggL pl v500 gunon z50 gunl e Choose Topics Manipulator e Choose Types motion system e Press Enter e Select Event preset time and change its value Press OK to confirm Remember that when using Event preset time the start of the r

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