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
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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
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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
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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
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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 -
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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
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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 -
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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
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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,
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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
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Series Controller, Explosion-Proof Type Kawasaki Robot Operation
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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
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C Series Controller, Explosion-Proof Type Kawasaki Robot Operation
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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
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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
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Series Controller, Explosion-Proof Type Kawasaki Robot Operation
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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
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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 -
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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
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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
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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