Manual robo kawasaki

Explosion-Proof Type Operation Manual Kawasaki Heavy Industries, Ltd. Caution Read this manual carefully before you use the robot actually and keep it safe, so as to fully bring out the functions of your Kawasaki Robot for yourself. 902031075DEB COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller

For safety FOR SAFETY This operation manual and the labels on the products are indicated with the symbols below for proper use and to avoid injuries or property damage. Read this manual and the related documents thoroughly before installation, operation, maintenance and inspection. DANGER Identifies procedures that, if not properly followed, can result in imminent injury or death. WARNING Identifies procedures that, if not properly followed, may possibly lead to injury or death. CAUTION Identifies procedures that, if not properly followed, may lead to human and/or mechanical injury. [ NOTE ] Denotes easily-misunderstood items regarding product performance, operation, and maintenance. i COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

For safety PREFACE This manual describes operational procedures for the Kawasaki C Series Controller, Explosion-Proof Type. Please read the Safety Manual thoroughly, a separate volume, before reading this manual. Also, this manual should be read before actual operation of the robot, and be stored for safe-keeping for later reference. This manual is written on the following assumptions: The robot is installed according to the Installation and Connection Manual (for robot arm), a separate volume. The controller is installed and connected according to the Installation and Connection Manual (for robot controller), a separate volume. The peripheral equipment is connected with the controller according to the External I/O Manual, a separate volume. This manual intends to explain the operational procedures as detailed as possible. As not all operations can be explained in one manual, only the major functions are explained. Therefore, only the operation of functions specifically described herein can be guaranteed. Because Kawasaki constantly strives to improve the quality of its products, this manual may be changed or revised without prior notice. This manual may not, in whole or in part, be reproduced or copied without the prior written consent of Kawasaki. Though this manual was prepared to be as thorough and accurate as possible, the authors apologize should any information be found in error. The screen examples in this manual may differ depending on software version. Some functions may not be installed depending on software version. This manual concerns operating procedures. It is not a guarantee of safety, and Kawasaki is not responsible for damages by the system or any industrial property troubles related with patent, as in the event of unforeseen trouble. MS-DOS is a registered trademark of Microsoft Corporation, USA. The other company and product names are also registered. All rights reserved. Copyright @ 2001 by KAWASAKI HEAVY INDUSTRIES, LTD. ii COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

For safety BASIC CONFIGURATION OF THIS MANUAL This manual describes the fundamental operational procedures for the Kawasaki C Series Controller, Explosion-Proof Type. Overview and basic operations that need to be understood first for using Kawasaki Robot Controller are explained. Operations which are common in every application and are peculiar to painting application are included and need to be read thoroughly. Many functions for making full use of the controller are also explained and should be read depending on the aim of the user. A glossary is included at the end of the manual as a reference for commonly used language and keywords regarding robots. The indicates a reference. For example, should be referenced. A-142 indicates that the auxiliary function 142 iii COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

For safety TEACHING METHODS The Kawasaki C Series Controller, Explosion-Proof Type can be programmed by a variety of equipment including the explosion-proof teach pendant. Select a teaching method that best suits the needs of your application and level of expertise. Explosion-proof teach pendant: Manual operation and teaching for the robot can be conducted using the explosion-proof teach pendant. Manual operation can be conducted only by the teach pendant. Multifunction panel: Various data can be displayed and set using the multifunction panel. Its keyboard screen is used for programming. PC (Option): It is possible to create an advanced application program by entering program instructions on PC. (This is called general programming.) Robot Language (AS Language) functions can be fully used, so that programs using advanced functions, such as coating operations, communication, and vision sensing, are possible. iv COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

For safety SYSTEM STRUCTURE The system structure of the Kawasaki C Series Controller, Explosion-Proof Type is as follows: Kawasaki Robot C Series Controller Multifunction Panel Explosion-Proof Teach Pendant Peripheral Equipment Multifunction Panel PC Explosion-Proof Type Controller PC (Prepared by the user) Explosion-Proof Teach Pendant KOSMOS Monitoring Software [For PC] (Provided by Kawasaki; Optional) [ NOTE ] Monitoring software for PC is run by the OS such as MS-DOS. OS needs to be prepared by the user. Multifunction Panel Controller Program selection Displays programs and steps Monitoring the signals Setting the repeat conditions General teaching Explosion-Proof Teach Pendant Regular operation Program selection Programs and steps Display Manual operation of the robot Monitoring the signals Setting the repeat conditions Positional teaching General teaching v PC Instruction entry of AS Language Keyboard entry of AS Language programs Loading/Saving of the programs into/from disk COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents CONTENTS SAFETY 1 ENSURING SAFETY.......................................................................................... 2 2 SAFETY IN GENERAL....................................................................................... 2 3 ROBOT SPEED LIMITATIONS.......................................................................... 3 4 ROBOT MOTION RANGE ................................................................................. 3 5 FIVE SAFETY RULES TO BE OBSERVED FOR KHI ROBOTS...................... 4 6 SAFETY DURING START-UP ........................................................................... 7 7 ENSURING SAFETY DURING TEACHING OPERATIONS............................. 8 8 DANGER PREVENTION DURING OPERATIONS........................................... 9 SWITCHES AND KEYS 1.1 SWITCHES ON THE CONTROLLER...........................................................1-2 1.2 MULTIFUNCTION PANEL ............................................................................1-4 1.2.1 SWITCHES ON THE MULTIFUNCTION PANEL ...................................1-4 1.2.2 LIQUID CRYSTAL DISPLAY ...................................................................1-5 1.2.3 KEYS ON THE LIQUID CRYSTAL DISPLAY .........................................1-6 1.2.4 KEYBOARD..............................................................................................1-7 1.3 EXPLOSION-PROOF TEACH PENDANT....................................................1-8 1.3.1 KEYS AND SWITCHES ...........................................................................1-8 1.3.2 DISPLAY DURING TEACHING.............................................................1-13 PROCEDURES FOR POWER ON/OFF AND STOPPING THE ROBOT MOTION 2.1 TURNING THE POWER ON.........................................................................2-2 2.2 TURNING THE POWER OFF .......................................................................2-5 2.3 STOPPING THE ROBOT MOTION ..............................................................2-6 BASIC OPERATION OF MULTIFUNCTION PANEL 3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL ...............3-2 3.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL ..............................................................................................3-4 3.1.2 STATUS SCREEN ...................................................................................3-5 3.1.3 OTHERS .............................................................................................. 3-6 3.1.4 STATUS SCREEN ...................................................................................3-8 3.1.5 SPRAY STATUS SCREEN......................................................................3-9 3.1.6 PROGRAM LIST SCREEN....................................................................3-13 3.1.7 MONITOR SCREEN ..............................................................................3-14 3.1.8 CURRENT POSITION SCREEN ...........................................................3-17 3.2 MOVING CURSORS ...................................................................................3-18 3.3 SELECTION BY ENTERING NUMERIC VALUES OR USING CURSOR OPERATION...............................................................................3-19 3.4 ENTERING CHARACTERS ........................................................................3-20 3.5 SELECTING PROGRAMS ..........................................................................3-21 3.6 SELECTING STEPS....................................................................................3-23 vi COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents MANUAL OPERATION 4.1 KEYS USED FOR MANUAL OPERATION...................................................4-2 4.2 PROCEDURES FOR MANUAL OPERATION..............................................4-3 4.2.1 TYPES OF THE MANUAL OPERATION COORDINATE SYSTEM.......4-5 4.2.2 SELECTING THE MANUAL OPERATION COORDINATE SYSTEM ..............................................................................................4-5 4.2.3 SELECTING THE MANUAL OPERATION SPEED ................................4-5 4.2.4 MANUAL OPERATION ON THE JOINT COORDINATE SYSTEM........4-6 4.2.5 MANUAL OPERATION ON THE CARTESIAN COORDINATE SYSTEM ..............................................................................................4-9 4.2.6 MANUAL OPERATION ON THE EASY COORDINATE SYSTEM ......4-11 4.2.7 GUN COORDINATE SYSTEM ..............................................................4-15 4.2.8 SELECTING THE OPERATION FOR TRAFERSE EQUIPMENT........4-17 4.2.9 MANUAL OPERATION OF THE TRAVERSE EQUIPMENT................4-17 TEACHING 5.1 OPERATION FOR TEACHING .....................................................................5-2 5.1.1 DISPLAY DURING TEACHING...............................................................5-2 5.1.2 REGISTERING THE PROGRAM NUMBER ...........................................5-3 5.1.3 TEACHING PROCEDURES....................................................................5-4 5.1.4 MANUAL POSITIONING........................................................................5-18 5.1.5 TEACHING THE MOVE INSTRUCTIONS ............................................5-20 5.1.6 TEACHING THE OTHER INSTRUCTIONS (ADD)...............................5-22 5.1.7 THE PROCEDURES FOR CHECKING PROGRAMS (CHECK OPERATION) .........................................................................................5-24 5.1.8 CORRECTING INSTRUCTIONS...........................................................5-25 5.2 EXPLANATION OF INSTRUCTIONS.........................................................5-29 5.2.1 SPEED INSTRUCTION .........................................................................5-30 5.2.2 SPRAY INSTRUCTION .........................................................................5-32 5.2.3 EXTERNAL OUTPUT INSTRUCTION ..................................................5-36 5.2.4 EXTERNAL INPUT INSTRUCTION ......................................................5-40 5.2.5 SMOOTH INSTRUCTION......................................................................5-42 5.2.6 CALL DATA BANK INSTRUCTION.......................................................5-46 5.2.7 TIMER INSTRUCTION ..........................................................................5-48 5.2.8 CALL PROGRAM INSTRUCTION.........................................................5-49 5.2.9 JUMP INSTRUCTION............................................................................5-50 5.2.10 CONVEYOR INSTRUCTION ..............................................................5-59 5.2.11 GUN CONTROL INSTRUCTION........................................................5-61 5.2.12 TABLE INSTRUCTION (OPTION)......................................................5-62 5.2.13 SENSING INSTRUCTION...................................................................5-63 5.2.14 MOVE INSTRUCTION ........................................................................5-64 5.2.15 OTHER INSTRUCTIONS....................................................................5-67 5.3 REPEAT OPERATION FOR CHECKING ..................................................5-71 PROGRAM EDIT WITH EXPLOSION-PROOF TEACH PENDANT 6.1 DISPLAY DURING EDITING ..........................................................................6-2 6.2 STARTING EDIT PROGRAM MODE .............................................................6-3 6.3 HOW TO EDIT INSTRUCTION.......................................................................6-5 vii COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents 6.4 HOW TO SEARCH INSTRUCTIONS .............................................................6-7 6.5 EDITING OF MOVE INSTRUCTION ............................................................6-10 6.6 ENDING EDIT PROGRAM MODE ...............................................................6-11 7 PROGRAM EDITING WITH MULTIFUNCTION PANEL OPTION 7.1 OVERVIEW OF PROGRAM EDITING ...........................................................7-2 7.2 PROGRAM EDITING SCREEN ......................................................................7-3 7.3 PROGRAM EDITING PROCEDURES ...........................................................7-4 7.3.1 EDIT OF AN ENTIRE STEP ....................................................................7-4 7.3.2 EDIT OF ALL DATA IN MULTIPLE STEPS ..........................................7-10 8 REPEAT OPERATION PROCEDURES 8.1 BEFORE EXECUTING REPEAT OPERATION .............................................8-2 8.2 METHOD OF REPEAT OPERATION.............................................................8-3 8.3 STOP AND RESTART REPEAT OPERATION PROCEDURES...................8-7 8.4 REPEAT CONDITION SELECTION ...............................................................8-8 8.5 WAIT OVERRIDE..........................................................................................8-10 8.6 SLOW REPEAT MODE.................................................................................8-12 9 AUXILIARY FUNCTIONS 9.1 AUXILIARY FUNCTION LIST .........................................................................9-3 A2 LOCATION & SPEED DISPLAY.........................................................9-6 A3 DATA TRANSFER...............................................................................9-8 A5 KILL PROGRAM..................................................................................9-9 A6 MIRROR CONVERSION (OPTION).................................................9-10 A9 DATA CONVERSION (OPTION) ......................................................9-12 A10 MEMORYPC CARD (SAVE)...........................................................9-13 A11 PC CARDMEMORY (LOAD)...........................................................9-15 A12 FILE DIRECTORY (FDIRECTORY) ...................................................9-16 A14 PC CARD AUX. FUNCTION...............................................................9-17 A40 AUTO TOOL SET (OPTION)..............................................................9-18 A41 ZEROING ............................................................................................9-19 A42 POSITION ERROR RANGE AT EMERGENCY STOP .....................9-20 A43 ENCODER ERROR RANGE..............................................................9-21 A44 ZEROING DATA SET DISPLAY.........................................................9-22 A46 INSTALLATION POSTURE................................................................9-23 A47 BASE COORDINATES .......................................................................9-24 A48 TOOL DIMENSIONS ..........................................................................9-25 A51 SOFTWARE LIMIT..............................................................................9-27 A53 ACCURACY ........................................................................................9-28 A55 SLOW REPEAT MODE ......................................................................9-33 A56 CHECK SPEED ..................................................................................9-34 A57 TEACH SPEED...................................................................................9-35 A70 MEMORY AVAILABLE .......................................................................9-36 A71 RECORD DATA/INHIBIT ....................................................................9-37 A72 AUTOMATIC PATH GENERATION ...................................................9-38 viii COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents A73 SPRAY ON/OFF .................................................................................9-47 A75 SYSTEM SWITCH ..............................................................................9-48 A76 HOME POSITION ...............................................................................9-51 A77 WORK SPACE OUTPUT (OPTION) ..................................................9-52 A78 CLEAR CHECK SUM ERROR ...........................................................9-53 A80 XYZ SHIFT (OPTION).........................................................................9-54 A81 JOINT SHIFT (OPTION) .....................................................................9-55 A82 TOOL SHIFT (OPTION)......................................................................9-56 A83 WORK SHIFT (OPTION) ....................................................................9-57 A87 PROGRAM ARGUMENT/COMMENT (OPTION) ..............................9-58 A90 SOFTWARE VERSION DISPLAY......................................................9-60 A91 ENVIRONMENT DATA.......................................................................9-61 A95 ENVIRONMENT DATA ..................................................................9-62 A96 ENVIRONMENT DATA OF PANEL....................................................9-63 A99 CHECK SPECIFICATION...................................................................9-64 A100 SYSTEM INITIALIZATION................................................................9-65 A101 BATTERY ERROR CHECK..............................................................9-66 A103 TOUCH PANEL SHORT CIRCUIT CHECK.....................................9-67 A110 TIME ............................................................................................9-68 A111 DEDICATED INPUT SIGNAL ...........................................................9-69 A112 DEDICATED OUTPUT SIGNAL.......................................................9-70 A113 DEDICATED SIGNAL DISPLAY ......................................................9-71 A114 GUN SPECIFICATIONS ...................................................................9-73 A114-1 GUN APPLICATION...................................................................9-74 A114-20 HANDLING CLAMP DEFINITION ...............................................9-75 A114-30 PAINTING/SEALING GUN DEFINITION ....................................9-76 A114-32 GUN RELATIVE DISTANCE CHECK .........................................9-77 A120 ERROR LOGGING ...........................................................................9-78 A122 OPERATION LOGGING...................................................................9-79 A124 MOTOR TORQUE INFORMATION (OPTION)................................9-80 A1241 WORNING LOG.............................................................................9-80 A1242 PEAK CURRENT...........................................................................9-80 A127 OPERATION INFORMATION (OPTION).........................................9-81 A130 PC PROGRAM RUN/STOP (OPTION) ............................................9-82 A1301 START (PCEXECUTE) ...............................................................9-83 A1302 ABORT (PCABORT) ...................................................................9-83 A1303 STOP (PCEND)...........................................................................9-84 A1304 CONTINUE (PCCONTINUE) ......................................................9-84 A1305 KILL (PCKILL)..............................................................................9-85 A1306 STATUS (PCSTATUS) ...............................................................9-85 A131 INTERFACE PANEL (OPTION) .......................................................9-86 A133 AS INSTRUCTION DEFINITION (OPTION) ....................................9-87 A140 ENCODER ROTATION COUNTER RESET....................................9-88 A142 PROGRAM QUEUE (OPTION) ........................................................9-89 ix COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents A142-1 DISPLAY ........................................................................................9-90 A142-2 REGIST..........................................................................................9-91 A142-3 INSERT ..........................................................................................9-92 A142-4 DELETE .........................................................................................9-93 A142-5 ALL DELETE..................................................................................9-94 A142-6 ENVIRONMENT SET ....................................................................9-95 A143 START DELAY (OPTION) ................................................................9-97 A143-1 COMMON DELAY DISTANCE......................................................9-98 A143-2 INDIVIDUAL DELAY DISTANCE ..................................................9-98 A143-2-1 INDIVIDUAL SETTING...............................................................9-99 A143-2-2 SET SAME DIST ......................................................................9-100 A143-3 MULTI START DELAY ................................................................9-100 A143-3-1 DISPLAY...................................................................................9-101 A143-3-2 CHANGE...................................................................................9-101 A143-3-3 DELETE ....................................................................................9-102 A143-3-4 ALL DELETE ............................................................................9-102 A144 INTERRUPT PROGRAM................................................................9-103 A149 TOOL REGISTRATION (OPTION).................................................9-104 A153 PROGRAMS IN DETAIL.................................................................9-105 A154 TOTAL REPEAT CYCLES OF PROGRAM ...................................9-106 A154-1 DISPLAY AND MODIFY..............................................................9-107 A154-2 ALL CLEAR..................................................................................9-107 A155 HOME POSITION CHECK AXIS SET............................................9-108 A158 DOUT FUNCTION ASSIGNMENT.................................................9-109 A159 HISTORY CLEAR ...........................................................................9-110 A166 PG PARTIAL DELETE....................................................................9-111 A167 SINGULAR POINT ALARM RANGE SET......................................9-112 A168 DIFF. OF WORK/AIR-CUT SPEED................................................9-113 A169 OPERATION CONDITION SETTING ............................................9-114 A172 SYSCOUNT DISPLAY/SETTING...................................................9-116 A172-1 SYSCOUNT DISPLAY/SETTING................................................9-116 A172-2 GENERAL SYSCOUNT SETTING .............................................9-117 A172-3 PRIVATE SYSCOUNT SETTING ...............................................9-117 A173 MOVING AREA XYZ LIMIT ............................................................9-118 A176 DATA BANK....................................................................................9-119 A176-1 LIST ..........................................................................................9-119 A176-2 EDIT ..........................................................................................9-120 A176-3 COPY ..........................................................................................9-121 A176-4 DELETE .......................................................................................9-121 A176-5 ENVIRONMENT SET ..................................................................9-122 A197 PASSWORD SET (OPTION)..........................................................9-123 A198 AUXILIARY FUNCTION SET (OPTION)........................................9-124 x COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents 10 OTHER FUNCTIONS THAN TEACHING BY EXPLOSION-PROOF TEACH PENDANT 10.1 LIST OF OTHER FUNCTIONS BY EXPLOSION-PROOF TEACH PENDANT .................................................................................................10-4 1-0 PROGRAM SETTING ............................................................................10-7 1-1 REPEAT STATUS DISPLAY .................................................................10-8 1-2 PRODUCT RATE VALUE SETTING.....................................................10-9 1-3 PRODUCT PAINT_IO RATIO..............................................................10-10 3-0-0 PRORAM LIST DISPLAY (DETAIL) ....................................................10-11 3-0-1 PROGRAM NUMBER LIST DISPLAY.................................................10-11 3-0-2 AVAILABLE MEMORY CAPACITY DISPLAY.....................................10-11 3-0-3 PROGRAM NAME REGISTRATION...................................................10-12 3-1 PROGRAM COPY ...............................................................................10-14 3-2 PTOGRAM LINK ..................................................................................10-15 3-3 PROGRAM DELETION........................................................................10-16 3-4-0 PARTIAL PROGRAM COPY ...............................................................10-17 3-4-1 PARTIAL PROGRAM DELETION .......................................................10-19 3-5-0 PARALLEL SHIFT................................................................................10-20 3-5-1 GUN-TIP DIRECTION SHIFT ..............................................................10-21 3-5-2 MIRROR IMAGE CONVERSION ........................................................10-22 3-5-3 TRAVELLER SHIFT WITH GUN TIP FIXED.......................................10-23 3-5-4 SHUTTLE RIGHT-LEFT CONVERSION (OPTION) ...........................10-23 3-5-5 CONVEYOR POSITION SHIFT (OPTION) .........................................10-24 3-6 AUTOMATIC PATH GENERATION ....................................................10-25 4-0 DATA BANK EDITING .........................................................................10-26 4-1-0 DATA BANK DETAILS DISPLAY ........................................................10-28 4-1-1 DATA BANK NUMBER DISPLAY........................................................10-28 5-0-0 GUN POSITION/ANGLE......................................................................10-29 5-0-1 JOINT VALUE DISPLAY......................................................................10-30 5-0-2 JOINT COMMAND VALUE DISPLAY .................................................10-31 5-0-3 ENCODER VALUE DISPLAY..............................................................10-31 5-0-4 POSITION DISPLAY OF TRAVERSE AXES ......................................10-32 5-0-5 TABLE POSITION DISPLAY (OPTION)..............................................10-32 5-0-6 GUN POSITION/ WRIST ANGLE DISPLAY .......................................10-32 5-1-0 EXTERNAL OUTPUT SIGNAL DISPLAY ...........................................10-33 5-1-1 EXTERNAL INPUT SIGNAL DISPLAY ...............................................10-34 5-1-2 INTERNAL SIGNAL DISPLAY.............................................................10-35 5-1-3 HOME POSITION SIGNAL DISPLAY .................................................10-36 5-2-0 GENERAL COUNTER DISPLAY.........................................................10-37 5-2-1 DEDICATED COUNTER DISPLAY.....................................................10-37 6-0-0 OPERATION CONDITION SELECTION (EXTERNAL OUTPUT)......10-38 6-0-1 OPERATION CONDITION SELECTION (INPUT WAIT) ....................10-39 6-0-2 OPERATION CONDITION SELECTION (CONVEYOR WAIT) ..........10-40 6-0-3 OPERATION CONDITION SELECTION (TIME WAIT) ......................10-41 6-0-4 OPERATION CONDITION SELECTION (CV TRACK MODE)...........10-42 6-0-5-0 OPERATION CONDITION SELECTION (SENSOR SETTING/ DOOR SENSING).............................................................................10-43 6-0-5-1 OPERATION CONDITION SELECTION (SENSOR SETTING/ CAMERA SENSING)........................................................................10-43 xi COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

6-1 6-2 6-3 7-0 7-1 8-0 8-1 8-2 8-3 8-4 8-5 8-6 8-7 Contents CURRENT CONVEYOR POSITION SETTING (CURRENT CV_POS) ..........................................................................................10-44 COUNTER VALUE SETTING..............................................................10-45 LOCATION VARIABLES REGISTRATION .........................................10-46 ERROR HISTORY DISPLAY...............................................................10-47 TOTAL PLAYBACK COUNT DISPLAY ...............................................10-48 MANUAL EXTERNAL OUTPUT EXECUTION (GENERAL SIGNALS) ..........................................................................................10-49 MANUAL EXTERNAL OUTPUT EXECUTION (SPRAY SIGNALS)...10-50 MANUAL EXTERNAL OUTPUT EXECUTION (FLOW RATE)...........10-51 MANUAL EXTERNAL OUTPUT EXECUTION (SHAPING/ PATTERN AIR).....................................................................................10-52 MANUAL EXTERNAL OUTPUT EXECUTION (AIR MOTOR/ ATOMIZING AIR) .................................................................................10-53 MANUAL EXTERNAL OUTPUT EXECUTION (HIGH VOLTAGE) ....10-54 MANUAL EXTERNAL OUTPUT EXECUTION (FLUSHING) .............10-55 MANUAL EXTERNAL OUTPUT EXECUTION (PUSH THINNER) ....10-56 11 AUTOMATIC TOOL REGISTRATION (OPTIONAL) 11.1 AUTOMATIC TOOL REGISTRATION FUNCTION - OVERVIEW............11-2 11.2 REQUIRED DATA FOR AUTOMATIC TOOL REGISTRATION...............11-3 11.2.1 TEACHING TOOL DIMENSIONS FOR 4 BASE POINTS ....................11-3 11.2.2 TEACHING TOOL POSTURE FOR TOOL Z DIRECTION...................11-4 11.2.3 TACHING TOOL ORIENTATION WHEN DISPLACED IN Y DIRECTION............................................................................................11-4 11.3 MEASURING TOOL DIMENSIONS POINTS FOR CAUTION ..............11-5 11.3.1 METHOD FOR TEACHING POINTS B, C (EXAMPLE)........................11-6 11.4 OPERATION METHOD .............................................................................11-7 11.4.1 PREPARATIONS FOR AUTOMATIC TOOL REGULATION................11-7 11.4.2 REGISTERING BASE POSTURE .........................................................11-8 11.4.3 REGISTERING MEASUREMENT VALUES .........................................11-9 12 CONVEYOR TRACKING (OPTION) 12.1 OVERVIEW OF CONVEYOR TRACKING FUNCTION............................12-2 12.2 OPERATION OF CONVEYOR TRACKING FUNCTION ..........................12-3 12.2.1 SELECTING CONVEYOR TRACING ..............................................12-3 12.2.2 CURRENT POSITION DISPLAY......................................................12-4 12.2.3 SETTING THE DATA ........................................................................12-5 12.2.4 SETTING ENVIRONMENTAL DATA................................................12-7 12.3 OPERATING THE SIMULATION FUNCTION ........................................12-10 12.3.1 SELECTING ....................................................................................12-10 12.4 TEACHING STANDARDS .......................................................................12-12 12.4.1 OVERVIEW OF TEACHING OPERATIONS BY CONVEYOR TRACKING .......................................................................................12-12 12.4.2 PREPARATORY OPERATIONS FOR TEACHING .......................12-15 12.5 TEACHING ...............................................................................................12-16 12.5.1 CAUTIONS TO BE TAKEN DURING TEACHING .........................12-16 12.5.2 EXAMPLES OF TEACHING ...........................................................12-16 12.6 REPEAT RUN AND PROGRAM CHECKING METHOD........................12-32 xii COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Contents 12.6.1 OVERVIEW OF CHECKING OPERATION....................................12-32 12.6.2 FLOW OF CHECKING OPERATION AND REPEAT RUN............12-33 12.7 INTERLOCK SIGNALS ............................................................................12-37 12.8 CONVEYOR POSITION SHIFT FUNCTION...........................................12-38 13 INTERFACE PANEL SETTINGS (OPTION) 13.1 OVERVIEW OF THE INTERFACE PANEL...............................................13-2 13.2 PROCESSING SEQUENCE ON INTERFACE PANEL ............................13-3 13.3 SELECTING THE INTERFACE PANEL SCREEN ...................................13-4 13.4 METHODS FOR SETTING INTERFACE PANEL.....................................13-5 13.4.1 SWITCH SETUP ...............................................................................13-5 13.4.2 PUSH BUTTON SETUP ...................................................................13-6 13.4.3 PUSH BUTTON WITH LAMP - SWITCH SETUP ............................13-7 13.4.4 2-NOTCH SELECTOR SWITCH - SETUP .....................................13-8 13.4.5 3-NOTCH SELECTOR SWITCH - SETUP.......................................13-9 13.4.6 PILOT LAMP - SETUP....................................................................13-10 13.4.7 DIGITAL SWITCH - SETUP............................................................13-11 13.4.8 DIGITAL DISPLAY - SETUP...........................................................13-12 13.4.9 TEXT WINDOW SETUP (OPTION).............................................13-13 13.4.10 SOFTWARE DEDICATED SIGNALS.............................................13-14 14 COUNTER MEASURES FOR ERRORS 14.1 SYSTEM INITIALIZATION .........................................................................14-2 14.1.1 CALLING UP INITIALIZATION SCREEN..............................................14-3 14.1.2 OPERATION PROCEDURES ON THE INITIALIZATION SCREEN ....14-4 14.2 NORMAL PROCEDURES WHEN ERRORS OCCUR .............................14-5 APPENDIX APPENDIX1 APPENDIX2 APPENDIX3 APPENDIX4 APPENDIX5 APPENDIX6 PROGRAM SHEET.......................................................................A-2 EXPLOSION-PROOF TEACH PENDANT MENU DIRECTORY LIST........................................................................A-5 MULTI-FUNCTION PANEL MENU DIRECTORY LIST ............ A-11 MULTI-FUNCTION PANEL AUXILIARY FUNCTION LIST....... A-12 INITIAL DATA SETTINGS ......................................................... A-16 OAT ............................................................................................ A-18 AS LANGUAGE LIST ................................................................................................ AS-1 ERROR MESSAGE TABLE.........................................................................................E-1 GLOSSARY................................................................................................................. G-1 INDEX............................................................................................................................ I-1 xiii COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

xiv COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY Memo

This section summarizes safety precautions to be taken prior to operating your Kawasaki Robot. Also, safety measures and the speed, motion range limitations on the robot are described. 1 2 3 ENSURING SAFETY ........................................................................................................ 2 SAFETY IN GENERAL ..................................................................................................... 2 ROBOT SPEED LIMITATIONS........................................................................................ 3 4 5 6 7 ROBOT MOTION RANGE................................................................................................ 3 FIVE SAFETY RULES FOR KHI ROBOTS..................................................................... 4 SAFETY DURING START-UP ......................................................................................... 7 ENSURING SAFETY DURING TEACHING OPERATIONS.......................................... 8 8 DANGER PREVENTION DURING OPERATIONS........................................................ 9 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY SAFETY

Safety [ Note ] The safety content described here applies only to operations with the robot unit and is not intended as a safety explanation for the whole system. 1 ENSURING SAFETY In order to ensure safety, all local, regional, municipal and national safety laws and regulations must be strictly observed. 1. The teaching and maintenance work on the robot must be carried out in accordance with labor safety laws and regulations. 2. The user should prepare safety regulations for working on the robot itself and observe these regulations responsibly. 3. In order to ensure safety, the following safety standards should be observed: JIS B8433, ISO10218, EN775, for robots used in production applications. 4. Safety administrators and full-time personnel should be assigned for work on the robot. In addition, a safety administrative system should be established as a means of providing thorough education regarding safety. 2 SAFETY IN GENERAL 1. The plant administrator should create safety and work regulations in consideration of structure of the line and peripheral equipment so that injuries from the robot are prevented. Moreover, appropriate steps should be taken so that safety education and work standards are created for the benefit of the workers. 2. Never use a Kawasaki Robot beyond the standard ability of the robot as set in the specifications manual. (Including specifications for payload, speed, motion range, environment, etc.) 3. Prior to starting operation, operators are expected to fully understand operation manuals and materials relating to the robot usage. And, care must be taken so that no injury occurs as a result of carelessness during operation. 4. Care must be taken so that none of the electrical components become loose or disconnected while the robot is energized. (e.g. connectors, circuit boards, etc.) 5. Also, care must be taken so that neither the explosion-proof teach pendant nor the multifunction panel are dropped or exposed to heavy impact, as they consist of a variety of precision instruments. 2 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety 3 ROBOT SPEED LIMITATIONS The maximum speed is limited to 250mm/sec. when operating the robot in check or teach mode from the multifunction panel or the teach pendant. 4 ROBOT MOTION RANGE A maximum possible motion range has been established for every robot model, unless the robot is given special specifications at the time of purchase. However, the motion range can be restricted to support the requirements according to the needs of the application. 1. Motion Range Limits via Software Motion range limits can also be set for the robot by software. WWARNING Setting only software limits on the robots motion range is insufficient as a countermeasure for preventing serious or fatal accidents. Mechanical stoppers as well as a safety fence must also be established. 2. Motion Range Limits via Mechanical Stoppers When mechanical stoppers are needed refer to the separate volume Installation and Connection manuals for the robot arm. 3 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety 5 FIVE SAFETY RULES FOR KHI ROBOTS WARNING Before operating, the following five basic points must be given attention in order to use the robot safely. Because the content here describes only fundamental points regarding safety, thorough reading of the separate safety manual is highly recommended. 1. Without exception, install the robot within a safety fence. Ensure that the robot is not easily approachable by people. 2. Provide a safety plug mechanism on the door of the safety fence. The safety plug should be installed so that the door cannot be opened without removing the plug and so that motor power to the robot will be cut off if the plug is removed during operation. 4 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety 3a. When performing work inside the safety fence, such as robot teaching or confirming that the work is complete, the worker must enter only after removing the safety plug. This will prevent the robot from being switched on to automatic run by another worker. 3b. In addition, during teaching operations an observer must be stationed in front of the controller and be ready and able to stop the robot at any time in case of an emergency. These duties can only be assigned to persons who have completed special training and are qualified to use the robot. 4. While the robot is operating automatically (running) or waiting in stand by mode, never enter the fenced area. 5 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

5. Safety Indicate the current status of the robot clearly and simply so that anyone can understand, for example with a sign showing automatic operation, teaching, emergency stop, etc. 6 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety 6 SAFETY DURING START-UP When starting up the robot, switch on the power to the motor and control panel. Pay special attention to the items below to ensure safety during start-up. 1. Before switching Motor Power on, make certain that the work cell is empty and that no one is within the safety fence, also confirm that there are no obstructions in the path of the robot. When switching Motor Power on, be ready and able to press the Emergency Stop switch in the event the robot moves abnormally. 2. Before starting operations in repeat mode, confirm that the work cell is empty and that no one is within the safety fence, also confirm that there are no obstructions in the path of the robot. 7 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety 7 ENSURING SAFETY DURING TEACHING OPERATIONS Confirm the contents of the teaching when creating programs or teaching point information to the robot. Pay special attention to the items below to ensure safety during teaching. 1. When entering the safety fence area, confirm that all safety and indicator devices, as well as the functions and devices for regulating the motion range of the robot are in good working order. Moreover, the worker should hold the teach pendant and perform teaching so as to be able to stop the robot or find cover immediately in the event the robot moves abnormally. 2. The robot must be installed in an area where the entire motion range of the robot can be overseen by an observer responsible for holding the Emergency Stop switch. When one worker (teacher) is inside the safety fence, the observer must be stationed outside and be able to press the Emergency Stop switch immediately if trouble arises. Duties including observing and working inside the safety fence are limited to those who have completed special training on robot usage. 3. In order to run at a safe speed during teaching, operate the robot at 10% (or lower) of the repeat speed when: jogging the robot to the teaching point, and confirming the teaching by moving either in one step increments or in 1 continuous cycle of steps. 4. During teaching, alert the attention of others so that none of the robotic instruments are handled carelessly or accidently. Instruments include: controller, multi-function panel, teach pendant, keyboard, etc. 5. When observer and teacher work together, one person must be designated as supervisor before the teaching operation can proceed. In addition, any signals used during teaching and the step order of the teaching must be understood and confirmed in advance. 6. While working within the area of the safety fence the observer and teacher must never take their eyes off the robot. 8 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety 8 DANGER PREVENTION DURING OPERATIONS Typically, the robot is running in a state of continuous motion during automatic operation. In order to prevent any accidents during automatic operation pay special attention to the items below. 1. During automatic operation, never enter the safety fence area under any circumstances. 2. In automatic operation, the robot may stop motion during timer mode or while waiting for input signal. Be careful at these times because the robot will restart motion as soon as the signal conditions are realized or the time count is completed. 3. If the installation of the tool or the grasp of the work is insufficient during automatic operation, the tool may become disengaged or the work may be ejected from the robot. To prevent these kinds of accidents, take extra care in checking the conditions of the tool attachment and the grasping of the work. Moreover, for applications in which the work is manipulated with a pneumatic device (hand, end-effector), set up a fail safe structure so that the work is not thrown as a result of an accidental cut in air or power to the solenoid valve. 4. When the robot stops due to some malfunction during automatic operation, confirm the contents of the error message shown on the display and perform an appropriate restoration of the system. Responsibility for resolving the error code numbers/messages that may arise should be assigned to teaching, operations and maintenance supervisors in advance. In addition, it is essential to clearly define the steps to be taken by each supervisor during system trouble. 9 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

10 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY Memo

SWITCHES AND KEYS This chapter describes the switches and keys for the controller, explosion-proof teach pendant, and multifunction panel. 1.1 SWITCHES ON THE CONTROLLER............................................................. 1-2 1.2 1.2.1 1.2.2 1.2.3 MULTIFUNCTION PANEL .............................................................................. 1-4 SWITCHES ON THE MULTIFUNCTION PANEL........................................... 1-4 LIQUID CRYSTAL DISPLAY........................................................................... 1-5 KEYS ON THE LIQUID CRYSTAL DISPLAY................................................. 1-6 1.2.4 1.3 1.3.1 1.3.2 KEYBOARD ..................................................................................................... 1-7 EXPLOSION-PROOF TEACH PENDANT ..................................................... 1-8 KEYS AND SWITCHES................................................................................... 1-8 DISPLAY DURING TEACHING .................................................................... 1-13 1-1 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY 1

1.1 1. Switches and Keys SWITCHES ON THE CONTROLLER This unit provides information about the switches located on the C Series Controller, Explosion-Proof Type. Backside of the controller Multifunction Panel Multifunction panel connector Operation panel 10 3 4 6 9 Control power switch (circuit breaker) 8 7 5 Communication port 1 2 Connector for the explosionproof teach pendant Explosion-proof teach pendant Control power switch (breaker): Switch to ON to turn on the control power of the controller. Switch to OFF to turn off the control power of the controller. 1-2 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1. Switches and Keys These switches are mainly for the regular repeat operation. No. Switch or light Function Illuminates when the control power of the controller is ON. 1 Hour meter 2 Indicates the total motor power ON time. 3 Illuminates when errors occur. initialization screen appears. 4 An error is reset when pressed. The error light is turned off after the error is reset properly. (Sequential errors cannot be reset.) 5 Switches the robot condition between operable (RUN) and temporary stop (HOLD). 6 Switches modes between TEACH and REPEAT. (This needs the attached keys.) 7 Repeat operation starts when pushed. This light illuminates when repeat operation starts properly. 8 Motor power is turned on when pushed. This light illuminates when motor power is applied properly. 9 Switches the method to start repeat operation. REMOTE: From the external start signal. LOCAL: From the Cycle Start button on the controller. Emergency Stop 10 Blinks when the The motor power is shut off and the robot stops when pushed. Motor Power light and Cycle Start light are turned off at the same time. (Control power is not shut off). Terms Teach mode: A mode for teaching by the remote control box for teaching (called explosion-proof teach pendant). Repeat operation is not possible in this mode. Repeat mode: A mode for starting repeat operation. Repeat operation: A robot condition in which taught operations are automatically repeated. 1-3 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1.2 1. Switches and Keys MULTIFUNCTION PANEL 1.2.1 SWITCHES ON THE MULTIFUNCTION PANEL Multifunction panel uses a large-sized color liquid crystal VGA display equipped with touch panel function. Keys are easily operated just by touching lightly on the liquid crystal display. These keys are for entering and editing various data. 1 4 3 2 No. 1 2 3 4 Switch or light Liquid crystal display PC card slot Contrast adjustment knob Touch panel pen Function Provides keys for entering and editing various data on robots. Also displays status, teaching and various data. For inserting a PC card. See A 14 PC card Adjusts the shading (brightness) of the display. Used for touch panel operation. 1-4 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1.2.2 1. Switches and Keys LIQUID CRYSTAL DISPLAY The liquid crystal display contains the following areas: 1 4 2 3 (The actual display may be different in some parts.) 1. System message area: Errors are indicated. 2. Title area: Displays the title of the selected status or function. 3. Auxiliary data area: Displays the present status and the teaching status of the present step. 4. Status information area: Displays status information. For example: M-OFF HOLD TEACH M-ON RUN REPEAT Repeat Accept 1-5 Slow repeat Inhibit COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1.2.3 1. Switches and Keys KEYS ON THE LIQUID CRYSTAL DISPLAY Keys associated with programs and steps: STEP PROGRAM pg1 PC 1 Key Function PROGRAM pg1 STEP Displays the program name that is currently selected. The program selection screen appears when pushed. Displays the current step number. 1 The step selection screen appears when pushed. PC Displays the PC program name that is currently selected. Keys for selecting screen: Key Function Used for teaching programs. Screens for teaching appear when pushed: AS TEACHING (option), PROGRAM INPUT (option). Toggles screens: STATUS, PROGRAM LIST, MONITOR, and CURRENT POSITION, PAINTING STATUS. Repeat conditions can be selected in the STATUS screen. Toggles screens among status, function selection, and keyboard entry. STATUS, FUNCTION, INTERFACE PANEL SETTING (option), KEYBOARD screens are equipped with auxiliary functions with which various data can be displayed and set. As for the multifunction panel with specification 2 (pull-down menu type), pushing STATUS and MENU keys drops menu selection keys below each key. 1-6 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1.2.4 1. Switches and Keys KEYBOARD The keyboard screen can be selected when the key on the multifunction panel is pressed. MENU Robot language programming and operation control of the robot are possible using AS Language in this screen. NEXT MENU key CTL+L key Backspace key SPACE key Switch SHIFT key ENTER key Function The BACK SPACE key is used to delete the entered characters one by one. NEXTMENU The NEXT MENU key switches the multifunction panel display from the keyboard screen to the status screen. The ENTER key is used for setting the AS Language commands, executing, and entering data. SHIFT The SHIFT key is used to enter the special symbols indicated on the top of the character keys by pressing with the other character keys. For example, when is pressed with the shift key, the symbol ! can be entered. NEXT PG Goes to the next page. SPACE key Displays the previously entered character strings (can go back a maximum of 10 previous entries). When the SHIFT key is pressed, this key turns into CTL+N key. CTL+N key displays the next character string to the present string. Used to enter a space. 1-7 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1. Switches and Keys 1.3 EXPLOSION-PROOF TEACH PENDANT 1.3.1 KEYS AND SWITCHES The explosion-proof teach pendant is equipped with the keys for robot manual operation, teaching programs, entering and editing various data. Liquid crystal display Trigger switch Emergency stop switch Backside of the explosion-proof teach pendant 1-8 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1. Switches and Keys Key SPRAY X-OUT GUN X-IN SMOTH DATA TIMER CALL JUMP CONVR SPEED SHIFT Function For entering the numeric value of 1. Decimal point can be entered when pressed with the shift key. For entering the numeric value of 2. Numeric value A (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 3. Numeric value B (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 4. Numeric value C (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 5. For entering the numeric value of 6. The minus can be entered when pressed with the shift key. For entering the numeric value of 7. Numeric value D (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 8. Numeric value E (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 9. Numeric value F (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 0. Used with the other keys. The additional values such as A F can be entered when pressed with the other keys. Moves the cursor up the screen (to smaller numbers). SHIFT Goes back to the previous screen. Moves the cursor down the screen (to larger numbers). SHIFT CLR Goes to the next screen. Cancels the numeric entry and clears all. 1-9 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Key END SHIFT END SUSPEND 1. Switches and Keys Function Returns to the main menu. Cancel the selection of program. The repeat operation ends when pushed during the repeat operation. Holds the present mode and moves to the other mode. The original mode appears when this key is pressed again. Returns to the upper screen. SET RT LFT FRNT SHIFT FRNT BCK Moves to the next screen when pressed for confirmation of menu selection or numeric value entry. Moves the robot in the right direction in the Cartesean coordinates or swivels the 1st axis to the right. The table axis rotates in normal (+) direction. Moves the robot in the left direction in the Cartesean coordinates or swivels the 1st axis to the left. The table axis rotates in reverse (-) direction. Moves the robot forward in the Cartesean coordinates or rotates the 2nd axis forward. Moves in the forward direction of the gun (only for the frame coordinates). Moves the robot backward in the Cartesean coordinates or rotates the 2nd axis backward. BCK Moves in the backward direction of the gun (only for the frame coordinates). UP Moves the robot upward in the Cartesean coordinates or rotates the 3rd axis upward. DWN Moves the robot downward in the Cartesean coordinates or rotates the 3rd axis downward. SWING RT Turns the gun to the right in the Cartesean coordinates or rotates the 4th axis to the right. SWING LFT Turns the gun to the left in the Cartesean coordinates or rotates the 4th axis to the left. BEND FRNT Rotates the gun upward in the Cartesean coordinates or rotates the 5th axis to the right. BEND BCK Rotates the gun downward in the Cartesean coordinates or rotates the 5th axis to the left. SHIFT 1-10 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1. Switches and Keys Key Function TURN UP Rotates the gun to the right in the Cartesean coordinates or rotates the 6th axis to the right. TURN DWN Rotates the gun to the left in the Cartesean coordinates or rotates the 6th axis to the left. FRAME Toggles the coordinate system at manual operation: Easy Gun Joint SHIFT FRAME ROB TRV TBL Selects the coordinate system to be switched with the coordinate selection key: Easy XYZ1 XYZ2 Selects an axis to be operated with the axis key: robot or other axes. LED toggles by pressing the device selection key as: Robot Traverse Table EQPMT Note: The detail of the device selection key may be different depending on the robot system structure. Toggles the manual speed of the robot and the peripheral devices among three levels: High Medium Low H M L SPEED Selects interpolation when recording positions. pressing the interpolation key as: Linear Circular (middle end) Joint L C J MOTION SHIFT MOTION STORE In teaching and edit modes, selects a type for correcting command codes from among Prohibit/Add/Modify/Delete/ Search. CRCT The circular LED is lit up in the middle of the circular arc and blinks at the end. During linear/circular interpolation toggles among: Retaining gun posture/wrist axis angle. Note: When retaining wrist axis angle, linear and circular interpolation LEDs are lit up and joint interpolation LED blinks. Records the present location as a teaching point. POS SHIFT LED toggles by CRCT RESET Changes the default correction mode to Prohibit/Add/Modify when correcting command codes on the command display screen for teaching and editing. Resets all the errors. 1-11 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

Key SHIFT 1. Switches and Keys Function RESET Resets errors one by one when more than one errors occur at the same time. SPRAY ON/OFF Selects whether or not to spray paint. When spraying (ON), the LED is lit up. SPRAY 1/2 Turns on the Spray 1 signal (outputs while key is pressed). SHIFT SPRAY 1/2 TEACH LOCK STEP Turns on the Spray 2 signal (outputs while key is pressed). Switch is designed to avoid repeat operation from being conducted accidentally during teaching. This switch needs to be ON after stopping repeat operation before entering into the safety fence. Cycle start cannot be conducted while Teach Lock is ON (LED is on). Toggles the way to move through steps, backwards or forwards, when in check mode (confirming the trajectory). Every time the key is pressed, the way to move from the first move in the screen toggles as: Move Command Continuous Jump STEP NEXT Shifts the program forward when in check mode (confirming the trajectory). STEP BACK Shifts the program backward when in check mode (confirming the trajectory). The keys below are the LED indication only: Key Function Indicates that the servo of the robot (manipulator) is ON SERVO ROB TBL when this LED is lit. Indicates that the servo of the table is ON when this LED is SERVO ROB TBL lit. Note: LED names may be different depending on the robot system structure. (The above is for standard specification.) Switch and push-button switch on the explosion-proof teach pendant: Key Function Emergency stop Turns OFF the servo power and stops the robot. switch Trigger switch Enables/disables the robots motion (enabled only while pressed.) These switches can be engaged only in teach mode. 1-12 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1.3.2 1. Switches and Keys DISPLAY DURING TEACHING The display during teaching appears as follows: 1 2 3 4 5 6 7 Correction mode (Prohibit/Add/Modify/Delete/Search), which is a sub-mode, is 1 displayed. Use CRCT key to change the mode. Displays coordinate system (Easy (XYZ1)(XYZ2)/Gun/Joint) at manual operation. 2 Use FRAME key to change the system. Displays how the program is shifted (per move/command/continuous/jump) when 3 pressing STEP NEXT and STEP BACK keys in check mode. Use STEP key to change the shifting method. 4 Displays program number that is presently taught. Displays present point number. 5 Counts MOVE commands in the program from the top and displays as a point number. 6 Displays operation guidance. Displays commands taught in each step below the 3rd line. The sequential number on the left indicates in command unit. 7 The highlighted number indicates that the the command execution is complete. The above example means that the commands up to the command unit 3, turning on the spray No.1, are executed. 1-13 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

1-14 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY Memo

This chapter describes the procedures for power on/off of the controller and for stopping the robot motion. 2.1 TURNING THE POWER ON ............................................................................................................2-2 2.2 TURNING THE POWER OFF ............................................................................................................2-5 2.3 STOPPING THE ROBOT ................................................................................................................2-6 2-1 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY 2 PROCEDURES FOR POWER ON/OFF AND STOPPING THE ROBOT MOTION

2.1 2. Procedures for Power ON/OFF and Stopping the Robot Motion TURNING THE POWER ON The procedure for starting the robot operation is as follows: WARNING When turning the Control and Motor Power of the robot controller on, thorough attention should be taken to prevent personnel from entering the motion range of the robot and the peripheral equipment controlled by the robot controller. The robot may move or operate accidentally when turning on the motor power, if the robot servo system is damaged. Turn the Control Power on. The version information is displayed on the teach pendant screen. Note: The version displayed depends on the software. Air purging process is automatically started. Note: This process is executed in pressurized explosion-proof type of robots such as KE and KF series. Steps 3-5 are skipped in the flame-proof type of robots. After confirming that the the purge air is supplied, step 4 is automatically started. 2-2 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

2. Procedures for Power ON/OFF and Stopping the Robot Motion The purging time starts to be counted down. Note: Purging time depends on the manipulator type. When purging is complete, the next screen automatically appears. After purging, the robot waits for the pressure to rise in the pressurized enclosure. When the pressure rises, the next screen automatically appears. The main menu appears. Turn the TEACH/REPEAT Switch to TEACH. Turn the MOTOR POWER on. The lamp is lit up. 2-3 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

2. Procedures for Power ON/OFF and Stopping the Robot Motion In teach mode, turning the motor power ON will not bring actual motor power to the robot immediately. The motor brake holds the robot at the current posture. After the motor power is on, the motor current is activated by pressing the trigger switch located on the backside of the explosion-proof teach pendant. Then, after 0.5 second, the motor brake is released and the robot becomes servo-locked. 2-4 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

2.2 2. Procedures for Power ON/OFF and Stopping the Robot Motion TURNING THE POWER OFF The procedure for turning the power off when finishing the robot operation is as follows. In this example external signals are not used. See the External I/O Manual, a separate volume, for using external signals. WARNING When shutting off the control power (breaker) of the robot, be sure to turn off the motor power by pressing the EMERGENCY STOP Switch located on the controller before turning off the control power switch (breaker). Press the EMERGENCY STOP switch and Turn the MOTOR POWER off. (The light goes off.) Turn the CONTROL POWER switch off. Turning off the motor and control power is complete. 2-5 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

2. Procedures for Power ON/OFF and Stopping the Robot Motion 2.3 STOPPING THE ROBOT MOTION The following emergency stop procedures are provided for stopping the robot motion immediately. These procedures can be executed regardless of the robot mode, repeat or teach. The robot motor power is shut off and the arm comes to a complete stop when executed. Controller EMERGENCY STOP Press the EMERGENCY STOP switch located on the controller. The MOTOR POWER and CYCLE START lights on the controller turn off. Explosion-proof teach pendant Press the EMERGENCY STOP switch located on the explosion-proof teach pendant. The MOTOR POWER and CYCLE START lights on the controller turn off. External equipment such as interlock board Press the EMERGENCY STOP switch. The MOTOR POWER and CYCLE START lights on the controller turn off. See the External I/O Manual (Interlock Signals), a separate volume. When stopping the robot motion using the above procedures, the ERROR light on the controller may turn on or an error message may appear on the display. For restarting the robot from the stopped condition, press the ERROR RESET switch and then the MOTOR POWER or CYCLE START switch. [ NOTE ] The EMERGENCY STOP switch should be used only for urgency during the robot operation. An emergency stop gives a sudden brake on the motor that drives the robot arm. This means that the robot is forced to stop by excessive power, and this may give a damage to the robot components. 2-6 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

2. Procedures for Power ON/OFF and Stopping the Robot Motion The following three procedures are provided for stopping the robot motion during repeat operation. Switches used for stopping the robot motion E-STOP SWITCH on the teach pendant E-STOP SWITCH RUN HOLD CYCLE START ON To REPEAT E-STOP CYCLE START OFF MOTOR POWER ON E-STOP MOTOR POWER OFF Arm in a complete stop Arm in hold Arm in motion TOGGLE SWITCH TOGGLE SWITCH To TEACH E-STOP Press Press 2-7 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

2-8 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY Memo

3 BASIC OPERATION OF MULTIFUNCTION PANEL This chapter describes the basic operation procedures for using the multifunction panel. 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL..............................3-2 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL ........................3-4 STATUS SCREEN.........................................................................................................3-5 OTHERS ........................................................................................................................3-6 STATUS SCREEN.........................................................................................................3-8 SPRAY STATUS SCREEN ...........................................................................................3-9 PROGRAM LIST SCREEN ........................................................................................ 3-13 MONITOR SCREEN................................................................................................... 3-14 CURRENT POSITION SCREEN ............................................................................... 3-17 3.2 3.3 MOVING CURSORS .................................................................................................. 3-18 SELECTION BY ENTERING NUMERIC VALUES OR CURSOR OPERATION .... 3-19 3.4 3.5 3.6 ENTERING CHARACTERS....................................................................................... 3-20 SELECTING PROGRAMS ......................................................................................... 3-21 SELECTING STEPS................................................................................................... 3-23 3-1 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

3. Basic Operation of Multifunction Panel 3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL or Press keys to display pull-down menu. MENU STATUS Select the desired key to switch screens. Status Display screen STATUS Status screen See 4 Status screen. See 3.1.6 Program List screen. Program List screen Monitor screen See 3.1.7 Monitor screen. Current Position screen See 3.1.8 Current Position screen. Spray Status screen See 3.1.5 Spray Status screen. 3-2 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel Menu screen Status screen See 3.1.4 Status screen, 3.1.5 Spray Status screen, 3.1.6 Program List screen, 3.1.7 Monitor screen (Output signal), and 3.1.8 Current Position screen Aux function screen See 9. Auxiliary Functions Setting screen for interface panel (option) See 13. Interface Panel Setting Keyboard screen (Option) See 1.2.4 Keyboard 3-3 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel 3.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL (1) Keys for switching screens (A): Left menu key for teaching (B): Right menu key for status display (C): Menu key (A) (B) (C) Status Status Display Program List Aux. Function Monitor Interface Panel Current Position Keyboard Spray Status Note: The left and right menu keys can be switched by pressing the keys indicated by (A) and (B) above. The selected menu key is darkened. (D): Returns to the STATUS screen by pressing the EXIT key on the function list screen of the Aux screen. (2) Keys for program and step selection PROGRAM STEP (A): Program selection and display key (B): Step selection and display key (C): PC program display key (A) (B) (C) A small screen for step selection appears. Switches to the program selection screen. (3) Others Program List screen contains two pages which can be switched by the PRE PG and NEXT PG keys. NEXT Program List Program List PRE PG (1/2) (2/2) Monitor screen contains Input, Output, and Internal Signal screens which can be switched by each key located on the downside. Output Monitor Monitor Input (Input Signal) (Output signal) Internal Output Input Monitor (Internal Signal) 3-4 Internal COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel 3.1.2 STATUS SCREEN (1) Status (2) Program List (3) Monitor 3-5 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel (4) Current Position (5) Spray status 3.1.3 OTHERS (1) Auxiliary Function 3-6 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel (2) Key board (3) Program selection (4) Step selection (When the status screen is displayed.) 3-7 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel 3.1.4 STATUS SCREEN Shows the current status and repeat conditions. Shows the monitor speed. Shows year, date, and time. Shows the repeat condition. Shows the current mode. The displayed color changes when turned ON and OFF. Displayed only when STEP ONCE is selected. Shows the step number and data. The second line is highlighted and shows the step in progress. Shows the location data of the step in progress. Set Items Repeat 10% Repeat condition Display Items E-STOP Motor power Cycle start Teach/Repeat Hold/Run Error Normal Release ext. hold Record accept Step forward Repeat Cont/Once Step Cont/Once Descriptions The repeat speed is indicated in percentage. See 8.5 Repeat Condition Selection Descriptions Turns on when the EMERGENCY STOP switch is pressed. Turns on when the MOTOR POWER switch is pressed. Turns on when the CYCLE START switch is engaged. Indicates robot mode; Teach or Repeat. Indicates the robot condition; Hold or Run Turns on when errors occur. Turns on when the robot is operating normally without any errors. Turns on when the stop release is engaged. The color changes when teaching becomes effective. Appears when STEP ONCE is selected. Indicates the status of the repeat operation programmed, one cycle only (Repeat Once) or continuous cycle (Repeat Cont). Indicates the program execution status, step by step (Step Once) or continuously (Step Cont). Indicates that RPS (Random Program Selection) function is enabled or RPS disabled. RPS is a function for selecting programs by external input Enable/Disable signal to the robot. Dryrun Indicates that the Dryrun mode is effective (ON) or not effective (OFF). ON/OFF 3-8 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel 3.1.5 SPRAY STATUS SCREEN Set items Spray output All ratio set Signal output Descriptions Switches to the Spray output screen. Switches to the All ratio set screen. Switches to the Signal output screen. Display items Production speed ratio Descriptions Indicates the production speed ratio data. Indicates the conveyor speed. (when the conveyor synchronization function is enabled.) Indicates the conveyor position. (when the conveyor synchronization function is enabled.) Indicates the production number. Indicates the repeat time. Conveyor speed Conveyor position Production number Repeat time 3-9 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel (1) Spray output Changes the manual spray output signal. Verify that the mode is in TEACH and the Teach lock keys on the explosion-proof teach pendant is OFF before changing. The screens for entering numeric values appear when the AIRMOTOR , HIGH VOLT keys are pressed. Display items Spray 1 Spray 2 Flow rate Shaping air / Pattern air Air motor / Atomize air High voltage Flushing Push thinner Flow rate upper Shaping air upper / Pattern air upper Air motor upper / Atomize air upper High volt upper FLOWRATE , SHAPING AIR , Descriptions Indicates the ON/OFF condition of the spray 1. Indicates the ON/OFF condition of the spray 2. Indicates the dedicated signal condition of the flow rate in numeric values for the corresponding signal. The numeric value screen appears for entering. Indicates the dedicated signal conditions of the shaping or pattern air in numeric values for the corresponding signal. The numeric value screen appears for entering. Indicates the dedicated signal conditions of the air motor or atomizing air in numeric values of the signal. The numeric value screen appears for entering. Indicates the dedicated signal condition of the high voltage in numeric values for the corresponding signal. The numeric value screen appears for entering. Indicates the ON/OFF condition of the dedicated signal for flushing. Indicates the ON/OFF condition of the dedicated signal for push thinner. Indicates the upper limit setting of the flow rate in numeric values for the signal. The numeric value screen appears for entering. Indicates the upper limit setting of the shaping or pattern air in numeric values for the signal. The numeric value screen appears for entering. Indicates the upper limit setting of the air motor or atomizing air in numeric values for the signal. The numeric value screen appears for entering. Indicates the upper limit setting of the high voltage in numeric values for the signal. The numeric value screen appears for entering. 3-10 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel (2) All ratio set Ratios for all the manual spray output signals can be set. Display items Flow rate Shaping air / Pattern air Air motor air / Atomize air High volt Descriptions Ratio for all the spray signals of the flow rate is indicated in percentage. The numeric entry screen appears when entering with keys. Ratios for all the spray signals of the shaping or pattern air are indicated in percentage. The numeric entry screen appears when entering with keys. Ratios for all the spray signals of the air motor or atomizing air are indicated in percentage. The numeric entry screen appears when entering with keys. Ratios for all the spray signals of the high voltage are indicated in percentage. The numeric entry screen appears when entering with keys. (3) Signal output Sets ON/OFF for the general output signals. The ON/OFF status of the signal is indicated by the LED on each key. Red : ON Blue: OFF Switched ON and OFF by pressing the keys. The signals assigned to the dedicated signal cannot be switched by the key. 3-11 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel (4) Screen for entering numeric values Numeric values can directly be entered from the Spray output and All ratio set screen. * The above is a screen called from the All ratio set/Flowrate. Flow rate Pattern air Atomize air High volt When the Setting range for manual spray output 0 upper limit (0 10000) 0 upper limit (0 10000) 0 upper limit (0 10000) 0 upper limit (0 10000) RETURN Setting range for All ratio set 0 200 0 200 0 200 0 200 key is pressed, the original screen appears again. 3-12 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel 3.1.6 PROGRAM LIST SCREEN Displays the current program list. Pressing the or key scrolls up/down the program steps by five lines based on the step with the cursor. [ NOTE ] When inserting, deleting, and modifying the program steps by teaching/editing from the explosion-proof teach pendant, the currently displayed screen does not reflect changes instantaneously. 3-13 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel 3.1.7 MONITOR SCREEN Indicates the status of the current input/output signals. The displayed color changes when the signal is ON. If the Built in sequencer function option is installed, the Input signals : IN*** Output signals : OUT*** Internal signals : INT*** INTEGER DATA The following IN/OUT signal keys appear in some versions. 3-14 key appears. COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

When the IN/OUT 3. Basic Operation of Multifunction Panel signal key is pressed: 3-15 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY C Series Controller, Explosion-Proof Type Kawasaki Robot Operation

3. Basic Operation of Multifunction Panel The signal names displayed on the monitor screen can be set by the user. The procedure is as follows: 1. Save the auxiliary data. SAVE/A File name. Or Select AUX 10. MEMORY PC CARD, then select 3 for Auxiliary data and save it. 2. Add the following between .AUXDATA and .END using the editor function of the PC that saved the file: For output signal, N_OX1 signal name 1 N_OX2 signal name 2 For input signal, N_WX1 signal name 1 N_WX1 signal name 2 For internal signal, N_INT1 signal name 1 N_INT2 signal name 2 Enter the desired signal name in . The name should be within 14 bytes. 1 64 can be set for output and input signals. 3. Load the file created by the editor. 4. When deleting the set file names, enter items without signal names between .AUXDATA and .END as shown below and load. N_OX1 N_WX1 N_INT1 When the same name is set as the dedicated signals, the name for the dedicated signal will be taken. [ NOTE ] The initial name is set when the system is initialized (SYSINIT). 3-16 COPYRIGHTED DOCUMENT

Manual robo kawasaki

Technology

electro magnetic

light emitting

schematic

paint circulating

protection

explosionproof

kf121 model

illegal array