Simpl friendly Kawasaki Robot KAWASAKI ROBOT CONTROLLER C SERIES CONTROLLER OPERATIONS AND PROGRAMING REFERENCE MANUAL KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION English [90203-1021DED]B— Kawasaki SSE ERG nr PHCSRAMUINE MANUAL Preface This manual is subject to change without prior notice and without our legal respon- sibility. Kawasaki pursues a policy of continuing improvement in design and specification of the product. The right is therefore reserved to vary this manual without prior notice. This manual is copyrighted and all rights are reserved by Kawasaki. This manual may not in whole or part be reproduced in any form or by any means without prior written permission from Kawasaki: This manual is prepared with the best care but anyway it is impossible to exclude any misinterpretation by the user or any spelling mistakes. In case of doubts or if the robot behavior is different from that reported in this manual please would you get in touch with the nearest Kawasaki or Kawasaki's agent. Kawasaki cannot anticipate every possible circumstance that might involve a potential hazard. If a procedure work method or operating technique not specifi- cally recommended by Kawasaki is used, you must satisfy yourself that it is safe for you and others. In this case you are completely responsible for eventual dam- ages on human bodies or thing. If you discover physical defects in the manual, Kawasaki will replace the manual at no charge during 90 days period after you purchased the robot. If you do not observe warnings and/or caution to be taken in the manual as de- scribed below, it might result in the serious injuries or damages on human bodies or robots. Therefor you must take extreme care to observe these warnings and caution. All rights reserved. Copyright C 2001 by KAWASAKI HEAVY INDUSTRIES, LTD. May 17, 2001© SERIES CONTROLLER OPERATIONS AND PROGRAMMINF MANUAL BE Kawasak Safety Whenever you see the symbols below in this manual or on the machine, read and understand their messages. Before installation work, read this manual and reference documentation Use them correctly. This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in serious injury or death. PRT This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in serious injury or death. oF eyN This caution symbol identifies special instructions or procedures which, if not strictly followed, may result in injury. PN ee This important symbol identifies special instructions or procedures which, if not correctly followed, could result in serious machine damage. [NOTE] or to emphasize a point or procedure, or to give a tip for easier operation. ii May 17, 2001BE Kawasaki CEEEAFONS ANE PROC RANRUING MANUAL Lo Wa 224 2244 221.2 2213 221.4 2.2.2 223 TABLE OF CONTENTS INTRODUCTION oe : ae be Mechanical Unit Mechanical Unit Design Specifications .. Robot Controller... Robot Controller Design Specifications. OVERVIEW ..... Major Features Of The Robot System Major Components Of The Robot System User Interface Devices : Multi Function Panel SRAM PC Card... ‘Small Teach Pendant Controller Switch Panel... Personal Computer. Optional Interface Panel... Robot Controller Main Circuitry Overview .. C-Series Controller Digital Servo Control Overview... Mechanical Unit Overview .. SAFETY .. Introduction Personal Safety ... Personnel Safety Categories Personal Safety .... Safety During Operation. Safety During Programming .. Safety During Inspection And Maintenance Safety Features = Work Envelope Drawings... May 17, 2001 11 C SERIES CONTROLLER: B—& Kawasaki CEES RS Me HOC UNAING MANUAL ———5.1.3.3—-Monitar creen, 5.1.3.4 Current Position Screen 5.2 5.3 5.4 5.5 5.6 TABLE OF CONTENTS: SWITCHES AND KEYS Controller . Control Panel Switches .. Multi Function Panel . Multi Function Panel Description ... Multi Function Panel Display Areas .. Multi Function Panel Touch Keys ... Program And Step Selection Keys Screen Selection Keys. Selection Keys for Auxiliam Program Data. Clamp And Signal Selection Keys....... : Ox (Output External) And Wx (Wait External) Selection Keys .. Record And Teach New Keys Aux Set & Disp Key . S Key... Check Mode Keys Robot Manual Operation Keys Keyboard...... eons POWER ON/OFF PROCEDURES Controller Power On/Off Procedures .. Controller Power On Procedures. Controller Power Off Procedures Servo Motor Power-On Procedures Servo Motor Power-On In The Repeat Mode Servo Motor Power-On In The Teach Mode Methods For Stopping The Robot .. Emergency Stop Switch ... Hold/Run Switch... Teach/Repeat Switch BASIC MULTI FUNCTION PANEL OPERATIONS Screen Selection Keys . Teaching Key Next Menu Key. Status Key Status Screen .. Program List Screens Cursor Movement Keys. Figure Input And Cursor Selection . Character Input Program Selection Step Selection .. 2 May 17, 20011 C SERIES CONTROLLER HB -~E Kawasaki SSE NSAID PHOCTIANG MANUAL 6.0 61 62 6.3 6.4 6.44 6.4.2 6.4.3 7.0 7A 72 7.3 7.3.1 74 75 7.5.4 75.2 75.3 7.5.4 7.5.5 TABLE OF CONTENTS MANUAL OPERATION. Keys Used For Manual Operation Manual Operation Procedures .. Operation of Optional Axes ... Coordinate Systems Joint Coordinates .. Base Coordinates. Tool Coordinates. eae 6-12, 6-16 RECORDING AND EDITING PROGRAMS Preparation for Teaching Program Names Creating a Program ..... Recording Program Steps . Checking Program Operation... Editing Program Information. "740 Ovenwrting Steps... 710 Deletion of Steps 71 Insertion of Steps . 2 TAZ Position Rewrite 712 TAB TAB seen TAT, 7-20 Auxiliary Rewrite Program Confirmation AAS Instruction Teaching(TEACH DATA)... AS Instruction Teaching(option) PROGRAM EXECUTION ... Be Program Selection oo : 83 Repeat Conditions .... 84 84 Repeat Condition Display ... Repeat Speed ... : Repeat Cont/Once Step Cont/Once .. RPS Off/On... Dry Run Off/On .. Running A Program... Monitoring The Program . Program List Screens Monitor Screens... ‘Current Position Screen ... i - it Stopping a Running Program... ett Slow Repeat Mode .. : 28-11 Wait Override..... 812 May 17, 2001 31 C SERIES CONTROLLER Bt -~E Kawasaki OFErATONS MND RROGT AiR eNUAL 9.22 9.23 9.24 9.25 9.26 9.27 9.27.1 9272 9.27.3 9.27.4 9.27.5 9.27.6 9.27.7 9.27.8 9.27.9 9.27.10 After. Wait Timer Switch. TABLE OF CONTENTS AUXILIARY FUNCTIONS Auxiliary Function List. Location & Speed Display, Aux 2 Data Transfer, Aux 3... Kill Program, Aux 5... Memory —> PC Card (Save), Aux 10 PC Card — Memory (Load), Aux 11 File Directory, AUX 12... PC Card Aux. Function, Aux 14 Manual Conduction, Aux 35 Zeroing, Aux 41 . Pos. Error Range at E-Stop, Aux 42 Encoder Error Range, Aux 43... Zeroing Data SevDisplay, Aux 44 Installation Posture, Aux 46 Base Coordinate, Aux 47 .. Tool Dimensions, Aux 48 Software Limit, Aux 51 Accuracy, Aux 53... Speed, Aux 54 .. Slow Repeat Mode, Aux 55 Check Speed, Aux 56 Teach Speed, Aux 57 ... Timer, Aux 58 . Memory Available, Aux Record Data (PRG CHG) Inhibit, Aux 71 Spray OrvOff, Aux 73... System Switch, Aux 75 Check.Hold Switch .... CP (Continuous Path) Switch .. Cycle.Stop Switch . OX.Preout Switch Prefetch. Sigins Switch QTOOL Switch : : Rep_Once (Repeat Once) Switch .....:.: RPS (Remote Program Selection) Switch Stp_Once (Step Once)Switch 927.11 9.27.12 9.27.13 9.27.14 9.27.15 9.27.16 9.27.17 Messages Switch . Screen Switch Autostart.PC Switches .. Errstart. PC Switch Dispio_01 Switch... Flowrate(option) . Hold.Step(option) 4 May 17, 20011 C SERIES CONTROLLER B-& Kawasaki Ce ONE HSS ANmANG MANUAL TABLE OF CONTENTS 9.27.18 WS_Compof(option) . 9.27.19 Spot_Optimize(option) 9.27.20 WS.Zero(option).... 9.28 Home Position, Aux 76 9.29 Clear Check Sum Error, Aux 78... 9.30 Software Version Display, Aux 90 9.31 Environment Data, Aux 91 . 9.32 Environment Data2, Aux 95 .. 9.33 Environment Data of Panel, Aux 96 .. 9:34 Check Spec. (Check Specification), Aux 99 . 9.35 System Init. (System Initialization), Aux 100 9.36 Battery Error Check, Aux 101 ... 9.37 Touch Panel Short Circuit Check, Aux 103 9.38 Time, Aux 110 9.39 Dedicated Input Signal, Aux 9.40 Dedicated Output Signal, Aux 112 9.41 Dedicated Signal Display, Aux 113.. 9.42 Clamp Specification, Aux 114 .. 9.42.1 Clamp Application .. 9.42.2 Clamp Condition ...... 9.42.3. Spot Weld Clamp Definition . 9.42.4 Spot Weld Control .. 9.42.5 Spot Weld Gun Definition 9.42.6 Handling and Clamp Data 9.43 Error Logging, Aux 120 9.44 Operation Logging, Aux 122... 9.45 Encoder Rot. Counter Reset, Aux 140. 10.0 ERROR CODES/HELP INFORMATION . 10.1 Error Recovery . 11.1.0 PROGRAM EDITING 11.1.1. Program Editing... 11.1.2 Program Editing Screen ......... 11-4 11.1.3 Program Editing Procedures 11-5 11.1.3.1 Partial Edit of Auxiliary Information . 11-5 11.1.3.2 Edit of an Entire Step 44.1.3.3—Partial Edit of Auxiliary Information for Multiple Ste ~__11.1.3.4~ Edit of All Data in Multiple Steps 1-17 11.2.0 INTERFACE PANEL. 11.2.1. Introduction to the Interface Panel 11.2.2 Processing Sequence..... 11.2.3 Selecting the Interface Panel Screen 11.2.4 — Setup Using Auxiliary Function 131 11-27 11-27 11-29 11-30 11-31 May 17, 2001 5C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL BE Kawasak TABLE OF CONTENTS Switch Setup... 11-31 PUSH BUTTON Switch Setup . . 11-33 PUSH BUTTON WITH LAMP Switch Setuy 11-34 11-35, 11-36 11-37 11-38 11-39 11-40 41-42 2-NOTCH SELECTOR SWITCH Setup. 3-NOTCH SELECTOR SWITCH Setup . PILOT LAMP Setup ........ DIGITAL SWITCH Setup DIGITAL DISPLAY Setup ... 11.2.4.9 TEXT WINDOW Setup(ption) 4.10 Software Dedicated Signal .. 11.3.0 ONLINE EDITING... 11.3.1 Auxiliary Data Edit Screen .. 11-43 11-44 11.3.2 — Step Select Screen .. 11-48 11.3.3 Clamp Data (Gun Data) Edit Screen . 11-49 11.3.4 OX Edit Screer .. 11-50. 11.3.5 WX Edit Screen .. 11-51 11.3.6 Location Edit Screen. .. 11-52 11.4.0 SEALING SPECIFICATION... 11.4.1. Call of Sealing Specification Screer 11.4.2 Teach Data Related to Gun 11.4.2.1_ Meaning of Teach Data . 11.4.22 Teaching Method of Teach Data ...... 11.4.2.3 _ Inputting Method of Gun Schedule 11.4.2.4 Manual Output of Gun .. 11.4.3 Setting of Gun Data... 11.4.3.1 GUN APPLICATION 11.4.3.2 GUN CONDITION 11.4.3.3 HANDLING CLAMP DATA ae 11.4.3.4 PAINTING SEALING GUN DEFINITION .. : . 11.4.3.5 Uniform Velocity Motion Function 11-66 11.5.0 SPOT OPTIMIZING FUNCTION .. 11.5.1 ‘SPOT OPTINIZING MODE and Hardware Dedicated Signal ....... 11.5.2 Data Processing When the SPOT OPTIMIZING MODE is ON/OFF ... 11.5.3 Abnormal Optimizing Data Value Detection Function ... 14.5.4 CLEAR SPOT OPTIMIZE DATA 11.5.6 Gun Press(Gun Response) Time Function .. 11.5.7 Gun Clamp Complete Input Signal, Gun Open Complete Input Signal 11.5.8 System Switch of Spot Optimizing Mode .. 11.6.0 OVERLOAD DETECTION 11.6.1 Overload Detection .... 6 May 17,2001Bt -—& Kawasak 11.6.2 11.7.0 DISPLAY OF OPERATING TIME AO AA A2 AS A4 AS AS AZ A8& AQ AA0 AN Al2 A13 A131 A13.2 ANS AAS ASA A15.2 A153 A154 A155 A156 A16 AAT ______4.25 Auxiliary Data Default Settings. SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL TABLE OF CONTENTS Torque Moritor..... APPENDIX .. Mirror Conversion, AUX 6 Data Conversion, AUX 9... Auto Too! Set, AUX 40....... Fixed Tool Dimensions, AUX 45 . Work Dimensions, AUX 49 .. Work Space Output, AUX 77 XYZ Shift, AUX 80 ....... Joint Shift, AUX 81 Tool Shift, AUX 82. Work Shift, AUX 83 Program Argumen/Comment, AUX 87 .. OX Specification, AUX 117... os AAG Motor Torque Information, AUX 124 .... ANB Warning Log. Peak Current... Operating Information, AUX 127 PC Program RUN/STOP, AUX 130 Start(PCEXECUTE) ........ Abort(PCABORT) Stop(PCEND)..... Continue(PCCONTINUE) .. Kill(PCKILL) Status(PCSTATUS) .. Interface Panel, AUX 131 AS Instruction Definition, AUX 133 .. Online Edit, AUX 135.... Tool Registration, AUX 14: Load on Arm, AUX 152. Operation Choose Function, AUX 196 Password Set, AUX 197 ....rsronn Auxiliary Function Select, AUX 198 .. Programming Sheets..... At see ABT ae ‘A.20— Programming Sheets .. 7S A21 Auxiliary Data Default Settings. -A-30 GLOSSARY Sere ee G4 INDEX INA May 17, 2001 71 ROLLER B—& Kawasaki GEEENFONG AND PROGRAMANG MARUAL TABLE OF CONTENTS LIST OF FIGURES Figure 1-1 Standard C Controller Figure 1-2 C5X Controller... Figure 1-3 European C Controller Figure 1-4 North American C Controller Figure 1-5 C70 Controller Figure 1-6 C80 Controller..... Figure 1-7 FS02/03, FC02 Mechanical Units . Figure 1-8 FSO6N, FS10E, FS20N, FS3OL, FS45N Mechanical Units . Figure 1-9 J-Series Mechanical Units i Figure 1-10 UT, UX, UZ-Series Mechanical Units Figure 1-11 Multi Function Panel(Type 1)... Figure 1-12 Multi Function Panel(Type 2)... Figure 1-13 Small Teach Pendant... : Figure 1-14 Standard Controller Switch Panel Figure 1-15 North American/European Switch Panel Figure 1-16 C5X Controller Switch Panel Figure 1-17 C70 Controller Switch Panel. Figure 1-18 C80 Controller Switch Panel. Figure 1-19 Optional Interface Panel... Figure 1-20 Circuit Board Block Diagram .. Figure 1-21 Servo Amplifier Block Diagram VOR 2=2SS50eGbOOHHKREELOD Figure 2-1 FS02/03, FCO2 Work ENVel0pe sinssneseussneneonsseseresesesensenneenes 2D Figure 2-2 FSO6N Work Envelope : Figure 2-3 FS10E Work Envelope Figure 2-4 FS20N Work Envelope . Figure 2-5 FS30L Work Envelope... Figure 2-6 FS45N Work Envelope . Figure 2-7 JAS/JC5/JS5/JW5 Work Envelope . Figure 2-8 JA10/JS10 Work Envelope Figure 29 JS30 Work Envelope Figure 2-10 JS40 Work Envelope .... Figure 2-11 UT-Series Work Envelope... Figure 2-12 UX70 Work Envelope... Figure 2-13 UX100/120/150 Work Envelope Figure 3-1 Standard C Controller ...... Figure 3-2 North American C Controller... Figure 3-3 European C Controller .... Figure 3-4 C5X Controller... 3-3 3-4 3-5 8 May 17, 2001Figure 5-13_Program Selection Methods. 1 (C SERIES CONTROLLER Kawasaki See AOAG ID Ac ML TABLE OF CONTENTS LIST OF FIGURES Figure 3-5 C70 Controller Figure 3-6 — C80 Controller Figure 3-7 Multi Function Panel(Type 1)... Figure 3-8 — Multi Function Panel(Type 2) Figure 3-9 — Multi Function Panel Display........ Figure 3-10 Robot System Conditions. Figure 3-11 Keyboard... Figure 4-1 Standard C Controller Figure 4-2 North American C Controller. Figure 4-3 European C Controller Figure 4-4 C5X Controller Figure 4-5 C70 Controller. Figure 4-6 C80 Controller. Figure 4-7 North American C Controller Switch Panel Figure 4-8 — C5X Controller Switch Panel Figure 4-9 Standard C Controller Switch Panel Figure 4-10 C80 Controller Switch Panel. Figure 4-11.70 Controller Switch Panel, Figure 4-12 Multi Function Panel(Type 1).. Figure 4-13 Multi Function Panel(Type 2). Figure 4-14 Methods of Robot Stoppage Figure 5-1 Screen Selection Keys. Figure 5-2 Teaching Menu Screen. Figure 5-3 Next Menu Screen. Figure 5-4 Status Menu Screen Figure 5-5 Status Screen........ Figure 5-6 Program List Screen Figure 5-7 Monitor Screen... Figure 5-8 Monitor Mode /O Graph Figure 5-9 Current Position Screen .. Figure 5-10 Cursor Movement Keys Figure 5-11 Figure Input or Cursor Key Selection Figure 5-12 Character Input.. 5-10 5-12 5-12 513 514 Figure 5-14 Program Delete Function Figure 5-15 Step Selection .. Figure 6-1 Manual Operation Keys(MFP Type 1) Figure 6-2 Manual Operation Keys(MFP Type 2)... Figure 6-3 Axis Key Definitions... May 17, 2001 9H- Kawasaki Geese bro sine VAN TABLE OF CONTENTS LIST OF FIGURES Figure 6-4 Speed and Inching Selectio Figure 6-5 External Axis Keys ... Figure 6-6 Robot Joint Coordinate Mode Figure 6-7 EH Robot Joint Movement... Figure 6-8 _JS-Series Robot Joint Movement. Figure 6-9 _U-Series Robot Joint Movement. Figure 6-10 Left Hand Rule Figure 6-11 Base Coordinate System Mode Figure 6-12 Base Coordinate System Movement Figure 6-13 Typical Linear Move Errors Figure 6-14 Tool Coordinate System . Figure 6-15 Tool Coordinate System Movement Figure 7-1 Program Select Screen we PD Figure 7-2 Character Set .... Figure 7-3 Teaching Screen Figure 7-4 OX Signal Key Display Figure 7-5 Clamp Settings .. Figure 7-6 Deleting Program Steps 71 Figure 7-7 _ Inserting Program Steps .. 712 Figure 8-1 Program Select... Figure 8-2 Repeat Condition Keys ant Figure 8-3 Repeat Condition Display Figure 8-4 Current Conditions .... Figure 8-5 Program List Screens Figure 8-6 Monitor Screens. Figure 8-7 Current Position .. : 8-10 Figure 8-8 Waiting Status Screen...... 812 Figure 8-9 Waiting Teaching Screen.. 8-412 Figure 8-10 Wait Override Screen... 8-13 Figure 9-1 Auxiliary Function Screen 194 Figure 9-2 Location and Speed Display 9-9 Figure 9-3 Data Transfer . 9-11 Figure 9-4 _ Kill Program... 9-12 Figure 9-5 Memory PO Gard = “OF Figure 9-6 PC Card» Memory (Load) .. 9-16 Figure 9-7 File Directory .. 9-17 Figure 9-8 PC Card Aux. Function se OAT, Figure 9-9 Manual Conduction 2918 Figure 9-10 Zeroing..... a) Figure 9-11. Position Error Range at E-Stop 921 10 May 17, 20011 C SERIES CONTROLLER: BE Kawasaki GEES AND PHO CELWNANG MANA Figure 9-12 Figure 9-13 Figure 9-14 Figure 9-15 Figure 9-16 Figure 9-17 Figure 9-18 Figure 9-19 Figure 9-20 Figure 9-21 Figure 9-22 Figure 9-23 Figure 9-24 Figure 9-25 Figure 9-26 Figure 9-27 Figure 9-28 Figure 9-29 Figure 9-30 Figure 9-31 Figure 9-32 Figure 9-33 Figure 9-34 Figure 9-35 Figure 9-36 Figure 9-37 Figure 9-38 Figure 9-39 Figure 9-40 Figure 9-41 Figure 9-42 Figure 9-43, Figure 9-44 Figure 9-45 Figure 9-46 Figure 9-47_Clamp Application. Figure 9-48 Figure 9-49 Figure 9-50 Figure 9-51 Figure 9-52 Figure 9-53 TABLE OF CONTENTS LIST OF FIGURES Encoder Error Range .. Zeroing Data Set/Display Installation Posture Base Coordinate .. Tool Dimensions Software Limit ‘Accuracy Speed... Slow Repeat Mode ... Check Speed. Teach Speed . Timer Settings Memory Available Record Data Inhibit .. Spray On/Off. System Switches CP Switch... OX.PREOUT Switch Home Position .. Clear Check Sum Error Software Version Display Environment Data Environment Data 2 . Environment Data of Panel... Check Spec. Screen System Initialization Battery Error Check .. Touch Panel Short Circuit Check . Time Dedicated Input Signal Dedicated Output Signal Dedicated Signal Display Clamp Specification ..... Clamp Setting Flowchart Weld Process VO... Clamp Specification Clamp Condition ... Spot Weld Clamp Definition Spot Weld Contrdl......... Spot Weld Gun Defini Handling Clamp Data.. May 17, 2001i csi :S$ CONTROLLER B—& Kawasaki CRATERS ID oHOG:AAMIGHANUAL Figure 9-54 Figure 9-55 Figure 9-56 Figure A-1 Figure A-2 Figure A-3 Figure A-4 Figure A-5 Figure A-6 Figure A-7 Figure A-8 Figure A-9 Figure A-10 Figure A-11 Figure A-12 Figure A-13 Figure A-14 Figure A-15 Figure A-16 Figure A-17 Figure A-18 Figure A-19 Figure A-20 Figure A-21 Figure A-22 Figure A-23 Figure A-24 Figure A-25 Figure A-26 Figure A-27 Figure A-28 Figure A-29 Figure A-30 Figure A-31 TABLE OF CONTENTS LIST OF FIGURES. Error Logging .. Operation Logging ... Encoder Rot. Counter Reset .. Mirror Conversion . Mirror Conversion Screen ... Data Conversion Auto Tool Set Teaching Tool Dimensions... Fixed Tool Dimensions .. Fixed Tool Dimensions and FLIN.. Work Dimensions Work Dimensions Orientation Work Space Output... Work Space Output Dimensions ... XYZ Shift Joint Shit. Tool Shift Work Shift Program Argument / Comment OX Specification. Output Timing... Motor Torque Information Warning Log . Peak Current Operation Information... PC Program RUN/STOP Start(PCEXECUTE) .. Abort(PCABORT) .. Stop(PCEND). Continue(PCCONTINUE) Kill(PCKILL). Status(PCSTATUS) . Interface Panel... AAS Instruction Definition .. Online Edit "A286 Figure A-3: Figure A-33 Figure A-34 Figure A-35 Figure A-36 Figure A-37 Tool Registration Load on Arm Operation Choose Function Password Set... Auxiliary Function Select. A29 A31 . A3t May 17, 2001H-~& Kawasaki Seon DPPOo massa Table |-1 Table I-2 Table 1-1 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table 3-8 Table 3-9 Table 3-10 Table 3-11 Table 3-12 Table 5-1 Table 7-1 Table 9-1 Table 9-2 Table 9-3 Table 9-4 Table 10-1 Table A-1 TABLE OF CONTENTS LIST OF TABLES Robot Specifications........ Robot Controller Versions ... STA Re Nes cer ecraec ees ears o ores oer osesoeera Control Panel Switches ... Multi Function Panel(Type 1) . Multi Function Panel(Type 2) .. Function of Program and Step Selection Keys Function of Screen Selection Keys . Function of Auxiliary Program Data Selection Keys Function of Clamp and Signal Selection Keys .. Function of Ox and WX Selection Keys ... Function of Record and Teach New Keys Function of Check Mode Keys .. Function of Robot Jogging Keys. Function of Keyboard Keys Status Screen Explanation... Auxiliary Data... Auxiliary Function List . Location and Speed Displays Memory to PC Save... System Switches Default Settings ... Error Codes / Help Information ...... Default Settings .. May 17, 2001 131 C SERIES CONTROLLER Kawasaki Soe ene Mn PASO ace INTRODUCTION 10 INTRODUCTION 11 Mechanical Unit 11.1 Mechanical Unit Design Specifications 12 Robot Controller .. 12.1 Robot Controller Design Specifications... May 17, 2001 Hi C SERIES CONTROLLER Kawasaki Cae eon oc ranaNG HALAL INTRODUCTION LO INTRODUCTION The C Controller Operations and Programming manual is designed to assist the user whose primary responsibility is to program and operate the robot on a daily basis. This, manual provides specific information on safety, basic operation, programming path and auxiliary data, setting the Auxiliary Data screens, and error information. 1.1 MECHANICAL UNIT The Kawasaki F, J, and U-series AC servo driven industrial robots are articulated coordi- nate-type robots designed for many applications in the industrial environment. The robot with its AC servo closed-loop drive system, is built with high rigidity. This design allows it to perform tasks that require high accuracy, speed, and wrist load capacities, while achieving significant energy reduction through the use of high efficiency brushless AC servo motors. The mechanical unit has six or seven axes depending upon the configuration of the robot. The major axes are: * _ JT4 (Reavis) rotary; rotation of the base + JT2(O-axis) out and in; rotation of the lower arm + _JT3 (D-axes) down and up; rotation of the upper arm The minor axes are: JT4 (S-axis) swivel; sets orientation of JTS for pitch/yaw motion JTS (B-axis) bend; provides pitch/yaw wrist motion * _JT6 (T-axis) twist; provides rotation of the tool only The auxiliary axis, if so equipped is: + JT7(V-axis) traverse; linear positioning of the mechanical unit The Kawasaki robot system supports Cartesian coordinate motion which includes: * Base (World) coordinates * Tool coordinates ‘These coordinate systems can be used when manually operating the robot in the teach node ane with variouss program instructions for shifting programs {positional data), defining —— tool center points, and recording positional data. Kawasaki robot systems use the left-hand-rule to determine the orientation of the base or tool coordinate system. 2 May 17, 2001Kawasaki © SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL INTRODUCTION 1.1.1. MECHANICAL UNIT DESIGN SPECIFICATIONS Table 1 Robot Specifications RowoT one. | reoarcu | re0s | Feoew | ree | roan | reso] Foun numberorares |_ ocr | eer | ocr | eer | oor | ear | sor ari] toveco | 2aareo | 2a0reee | e00vees | _tooveoe | veoreee [10070 sya | _terieec | —so0vees | 2007eee | 1a0veee | wovkeo | _wovneo | _va0reee B13 | teoisos | va0reec | _a50reee | _200%ee | oses | —te0veee | _10'mee Maimam | ire | eraee | Bes | eaves | 060700 | savrmec | Bee | DOT Ts | wovees | 180"eo | aa0reee | se0vseo | s00%00 | _2a0ieee | _2OTbee Te | _eovisos | _s60vsos | ra0reec | _s00voc | sooveec | aaoieec | _oo'eee a 7200 mec] 1200 mee |1000 ree] 1000 mies [1000 mee simu Urea [o00 wee [1000 mos [1000 mec] 100 mane | 500 rn | 1500 mos 50 mies vi| sar _[ seo | se | mer | ser | sar | neo ce a or | aOR a3 | saoovt80" [-aorteon | aasor | azo [ azo | azo | azo Work Envelope] ra | 06 | 00" | avo" _[ save" | savor | avon | sare (tees) JTS +4135" 4135" 2145" 145" 2145" £130" £130" ve | _sseor | sseor | _sseor | sseor [sano (| er [seem de es ee ee ee ers Max Paya’ |? z @ 7 | = 2 a wa | 40nn | Seanm | von | ain | sanm | ireanm | W04Nm wat ated! 5 | _aonn | saenm | worn | a1enm | soanm | Weanm | roan we | 20mm | 2oenm | eonn | een | 196Nm | 980Nn | 980Nm mnaag[ iH | eoment | oman [ cxoni| oonané | ommnt| ratont | ronwat Womenet | oS | eoretgn™ | owanant | oxngnt| oeston® | omen [rae | wom ieee | sara) Goomne | eoasen| cemuanl | teuues | caminn [tease |ceoen Tepestbtiy | 2000 | soos | soos | oon | oa | wore | vons wi | ore [orm | tom | tom [atm | sae) azhw 2 | caw | cam | tom | tow | atm | sam | 42hv a [oorsw [cove | oats | oats | tomy step st] ee ee ———— JTS | 0.03 kw 0.03 kw 0.1 kw 0.1 kw O2kw OATS kw 0.475 kw wie | 0004 | 000 foam | orm | aam | oars | oars a7 [otk | otkw 1.0 kw 10 kw vow | aikw | 2tkw wees [oes] 200 | 2m | vom | 20m | 210% | seone | ss000 May 17, 2001 BB—& Kawasaki C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL INTRODUCTION Table |-1 Robot Specifications (Continued) ROBOT MODEL | IWS 35 Ws vso | veo | _vso Number of Axes 6 67" 6(7y e(7y e(7y 6(7y ai | teovees | 1200s | _ 2z0vecc | _te0rsec | _1e0vsec | t00ve0 a2 | teowec | re0%ec | _te0veec | _s20veec | _ra0veec | _ 1207800 [are [ etormee | etoreoe | 200%ec | te0ve0e [160700 | 160 Ve00 Meximum (Tra | aaviees | ‘00sec | sadinec | 200700 | aa0eee | _2ad'hee Ts | save | sa0'%ec | #20%ec | ze0veec | 200veec | 240rr00 Te | Tavnec | 7aovec | ra0veec | _coovses | stornec | _ 340"0e a7 1200 mised} 1200 mmveod 1200 mnveed 1000 mmised 1000 mmvsed Maximum Unear | 099 mnveee] 1000 mnveoq 1000 mmvead| 1600 mmveed 1600 mveed 1600 mmisec| wi [ aver | ste | ater | sve | sor | ser 2 [aorta | svaorra0] sorte | aor] sors20| aor won [22 | szeor2r0: | va00rzre| szo0rare | szomrare | vzaorzre | 2507-270 envelope| JT [aan no | sar | sare | aa | sare (stoke) we soe | nae as | awe | eno | s10 wre [sss | sso | sor | sam | saor | ase JTT | ———— _| Custom Lengths} Custom Lengths} Custom Lengths | Custom Lengths | Custom Lengths Max Paylosd 3 5 3 10 20 ny wa [_renm | 7onm | 7anm | 21enm | venm | 176Nm wast rates] rs | 7enm | ranm | 7enm | axenm | wenm | 1eNm we | _20nm | 20Nm | 20Nm | eanm | conm | o0Nm JT4 0.17 kgm? 0.17 kgm? OAT kgm? | 0.48 kgm® 6.1 kgm? B.A kgm? Wrst Rated Moment of | JTS 0.17 kgm? 0.47 kgm? OAT kgm? | 0.48 kgm* 6.1 kgm? 8.1 kg m? inertia 376 | o06kam? | ooskam? | 006k9m? | oA0Kgm? | 20am" 25kgm* Repeatapiity | 2005 | x00s | 2008 zor_| x018 | 2018 ai] tom | tom | tom | som | 42m | 4200 wa [100 | 100 | ton | 10m | aame | 42m | 04 ew] — 04 oe}. 708 ate} ate im soune| 4 | amr | one | nue | came | ome | tome ws [orm | orm | orm | orm | 10K | 10Kw we [01m | oamw | orm | cam | 100 | 1066 wv ete: 1.0 kw 1.0 kw 1.0 kw 24 kw 21 kw Wass [eww | 20m | 0K0 voKg | 100K | 700K | T00K9 May 17, 2001BE Kawasaki INTRODUCTION SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL Table |-1 Robot Specifications (Continued) ROBOTMODEL | UTI] UTIz0 | uTis0 | uTz00 | _UuxTo Ux100 Number of Axes 6c 67 ites 6c ey 6(7y GT | ta0%sec | t20%sec | _t00%ec | _100%00 | _1207ec | 120 7e00 B72 | 100%ee | to0%eec | _eovsec | _e0r%aec | 120/600 | _120%0e B73 | t20%0c | _1207%sec | t00%sec | 70sec | 12070 | 120/00 Maximum [ira [ se0veec | _150veec | 126%—0c | 120veec | _150%m0e | 10000 B15 | teoec | 150%eec | 125veec | 1t0vees | 150%ee0 | 150700 Wis | 2dveec | e0veec | 200%e0c | 200%Ge0 | 20070 | _2407e0 [7 | 1000 mnvsec | 1000 mnvsec| 1000 mmsee| 1000 msec] 1000 mm/sec] 1000 mmleac TaarTimepsea” | 2#00%mvaee| 2400 mnveec| 2400 mnveec [2400 mec) 2400 mnave| 2400 mre amt £180" +180" +180" +180" +180" +180" a2 | sever | ssve0 | vssver | vssve0 | roves | +70165 wore [272 | rosr-105" [ sosr-105° | va6r-t05" | ve5r-t05 | voov-1e | soor-110" Envelope| va | =260" | _=280" 260° | 2200" =260 | 2080" (Stroke) wis | star [nia mas | a2 zee | a2 are | ss6r | 200° zee | 28007 za | 2360" JTT | Custom Lengths | Custom Lengths] Custom Lengths] Custom Lengths] Custom Lengths | Custom Lengths Max. Payload 100 120 450 200 70 100 Jv 539 Nm 686 Nm 833 Nm 1176 Nm 490 Nm 539Nm wnctRated| is | saowm | ca6nm | ssanm | tveNm | aonm | 690Nm Wie | 3Nm | 202m | a41Nm | 686Nm | aoanm | 33Nm See JT4 30.2 kgm? 49.0 kgm? TAS kgm? | 124.4 kgm? 49.0 kgm? 30.2 kgm? Moment of | JT5 | 4stkom? | sackgm? | 715k9m? | taotngm® | saokom? | 44.tkgm? wee ED 2estgm? | a74kgm? | stangm? | 77akgm? | 274kam? | 245kgm* Repeatability | _=05 205 205) 205 205 205 ati | som | 5010 sow | som | S0KW 5.0 kw wz] som | 50KW sow | som | S0Kw 5.0 kw | 213} —6.0 kw. 5.0K 5.0-kw—} —5.0-kw. 5.0-kw 5.0kw—] eve Source | JT4 | 25h | _25hw 250 | _ainw | 25hw 25 kw sts 25h | 25h0 2s | ain | 25hw 2.5 hw 376 25 kw 2.5 kw 2.5 kw 3.1 kw 25 kw 2.5 kw a7 | 25mm | _2shw 25h | 25kw | 25hw 25kw Mass 6 Axes 1500 kg_ 1500 kg 1500 kg 1600 kg 1430 kg. 1400 kg May 17, 2001Kawasaki SEES OMENS anu MANUAL INTRODUCTION Table |-1 Robot Specifications (Continued) RouoTwoDEL | _ux@e | _uxiso | _uxao0 | ux | _uzio0 | _uziao [veo Nomberotavee | er | sor | ocr | ear | ear | cor | sor ari aoe [to0rmee | tonnes | _voornec | vavrnec | 0vnse | 100700 “ra | a0rees | scrrmss [ones | raw | trie | torreeo | score Tra | _20reee | seovnes | _o0vmes | erase | siovnen | vovec | 100% ema wesmum [se | scores | to5rmeo | tarene | cove | se0rmec | 1e0rmeo | 125m Ts] sovsee | astaee [Horses | 7oVse | seve | 1e0rbeo | 15eee we | BOvaee | somes | —200ree | va6vooe | 2t0%hec | —eOvaec | 200% 7 | 0 ss 060 ie 00 ec1090 mec] 100 mec] 100 es [a0 ee a ar ee Raima rat [oo van | 200 wo] 200 rc] 2100 ler 20 [200 me [OD aa] ser [ ate | sieor | ate [ arom [ater [nar we | sore | vores | ores | rover | roves | vores | rrr | saorror | vooremer | waar | voorer | vaesrrion | eanorosy | aes 08 Work envtope| ava [ zz00" | azar_| _sza0r_| azar | azar zoo | azar (owe) we | awe eas [eve | evar eas [ata ates wre | seo sseor | _eaeor | sacar [sae [aeons 7 [esto toa |enem Lee Con ree] Cntr argh | eg ato oe mon Le WaxPayiet | 120 | 10 | m0 wo] 0 =| 0 Wa |_eenm | enn | ion | wenn | mown | eon | ean wostratal rs | sanm | aon | sewn | ‘wenn | soon | wenn | een wre [oem | ainm [sewn | estnim | aianm | aeenin | 44 Nn a Ta] wom | Tame | atom | veotem | stow? | _eitemt | amen? iit Rata Wonertor | 75 | sown | rae [ winn'| ween? | swe | aren | Tae irrta sre | aan | aameat | Teen? | monn? | aston? | _maront | aisnem? Repeauiny [208 | vos | ws | os | wa | ooo | mea Tr [_som | som | sow | sow | som | tom | som Jz | som | sow | sow | com | sow | tom | som Ow [som | Som | 0m | som | SO | BO] pontaree[ Jt4] 28 [came | ate [atm [26m | asm [26m we] asi | eso | atm | anew | 25m | osm | 25m we | ase | 2smy | atm | anew | 2am | 26m | 260 a7 |_asew | 26m | 25m | osm [28m | asm | 26m vss errs va009 | 150016 | 155049 | Woony [10019 | te00x@ | 10080 6 May 17, 2001BE Kawasaki C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL INTRODUCTION 1.2 ROBOT CONTROLLER The Kawasaki C-type controller consists of printed circuit boards, multi function panel or teach pendant, optional interface panel, and servo amplifiers. The controller is available in four versions; standard, North American European, and C5X Controller. Table 1-2 lists the controller type (Cxx) for the various robot models. Table |-2 Robot Controller Versions C Controller Type and Code Standard | NorthAm.| European} —C5X Robot Model] Specification] Specification] Specification] Specification] [Jas cit JA10 cn JCS ct 30 c40 JM10 ct JSS ct 30 C40 JS6 ci JS10 cit 30 C40) JS30/40 C20 C31 cai IWS cit 30 C40 uD. C22 woot C21 C32 ca2 cs2 UXx200 C21 C32 ca2 fone c70 c70 c70 FSO6N c11,c8o_| c30,c80 | C40, C80 FS10E cit C30 cao CH C30 40 C50 FS30L cit 31 cat FS45N c20 31 cat cst May 17, 2001C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL H—& Kawasak INTRODUCTION 1.2.1 ROBOT CONTROLLER DESIGN SPECIFICATIONS Control System: 32 bit RISC main CPU 32 bit RISC CPU for multifunction panel unit 32 bit RISC servo CPU controller (one per 3 axes) Software controlled AC servo drive system using PWM (pulse width modulation) circuitry. Number of Axes: 6 standard; 7th optional Motion Control: Teach mode- — Joint Base Tool Repeat mode - Joint move Linear move Circular move (optional) Memory: CMOS RAM Memory Capacity: Standard - 1024 KB (approx. 5000 steps) Optional - 4096 KB (approx. 35,000 steps) Accuracy: Four levels of accuracy for block step programs, UX/UT-series Adjustable between 0.5 mm - 5,000 mm UZ-series Adjustable between 0.3 mm - 5,000 mm JC5/SWS/JS5/1 0/30/40 Adjustable between 0.1 mm - 5,000 mm FS30L/FS45N Adjustable between +/-0.15 mm FS10E/FS20N Adjustable between +/-0.1 mm FSO6N/FSO3 Adjustable between +/-0.05 mm Fso2/FCo2 Adjustable between +/-0.03 mm 8 May 17, 2001Kawasaki © SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL Speed: Data Editing: Software Features: VO Signals: Dedicated Signals: INTRODUCTION 10 levels of speed for block step programs (adjustable between 0% - 100%) Step insertion and deletion, and rewriting of auxiliary and positional data. Continuous path motion control - CP ON/OFF Time delays Coordinate modification Process control programs (3) Peripheral equipment control Interrupt signal control Error interrupt control Input of real, string, and integer variables Local variables Subroutine calls with arguments (maximum stack = 20) Program weld schedules Servo shutdown timer Auto start function 32 inputs/32 outputs (C4X,C5X; 128 : C1X, C2X, C70, C80;96 maximum) (including dedicated signals) RUO (option) Relay circuit 320 A-B PLC 6410 Weld controller 32/0 Non-retentive 128 Retentive 16 Timers 16 Counters 16 Message display 64 Slogic status 16 Control Net (option) Motor Power ON Error Occurrence Outputs - ‘Automatic CYCLE_START Teach Mode HOME1 HOME2 Power ON RGSO May 17, 2001BE Kawasak © SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL Dedicated Signals: Error Messages: Special Features: Multi Function Panel: (option) INTRODUCTION Inputs - Ext. Program Select (RPS) Enabled Ext. Motor Power ON, Ext. Error Reset Ext. Cycle Start Ext. Program Select Start (JUMP) JUMP_ON JUMP_OFF JUMP_ST Ext. Program Select Start (RPS) RPS_ON RPS_ST Number of RPS Code Signal First Signal Number of RPS Code Program Reset Ext. Hold (EXT_IT) Ext. Condition Wait (EXT_WAIT) Ext. SLOW REPEAT MODE Error code messages, self-diagnosis, error logging, operation logging Program check mode Adjustable restriction of JT1 Terminal box on robot arm (optional) Robot application interface panel (optional) Overtravel limit switch - JT1 (JT2, JTS option) Power lockout (C3X, C4X,C5X, C80 controller) Ethernet (option) Deadman safety switches VGA color LCD Touch panel Teach-lock function Emergency stop switch Pen for touch panel PC card insertion section Teach Pendant: (option) Deadman safety switches Teach-lock function Emergency stop switch Membrane switch keypad Alphanumeric LCD May 17, 2001BE Kawasak Supplemental Data Storage: Power Requirements: C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL INTRODUCTION PC SRAM Memory Card 1,2 or 4 MB, PCMCIA 2.1 Slot Floppy disk drive (option) Personal computer (option) Standard Spec.: North Am Spec.: OSX Spec.: European Spec.: 3-phase 200/220 VAC. 3-phase 400/440/460/480/515/575 VAC 3-phase 380/400/415/440/460/480 VAC C70 Spec.: Singl-phase 200-240 VAC C80 Spec.: Tolerance: 41-10% Frequency: 50/60 Hz C70 Spec.: Singl-phase 200-240 VAC Rated Load: 10.5kVA / C70 1.5kVA / C80 3kVA Ground: less than 100 ohm ground line separated from welder power ground Dimensions: Standard Spec.: Wx D x H, 460.8mm x 430mm x 1240mm North Am. Spec.: WxDxH, 550mm x 500mm x 1150mm European Spec.: WxDxH, 550mm x 500mm x 1150mm C5X Spec.: WxDxH, 550mm x 600mm x 1150mm C70 Spec.: WxDxH, 270mm x 500mm x 470mm. C80 Spec.: WxDxH, 470mm x 350mm x 850mm. Mass: Standard Spec.: approx. 80 kg North-Am.Spec.:-250-kg European Spec.: C5X. Spec: 260 kg C70 Spec.: 30 kg C80 Spec. 60 kg May 17, 20011 ‘C SERIES CONTROLLER: B= Kawasaki ECA ene ee INTRODUCTION Accuracy, I-8 auxiliary axis, -2 Base (World) coordinates, -2 CMOS RAM, I-8 coordinate systems, -2 Data Editing, |-9 Dedicated Signals Inputs, I-10 Outputs, 1-9 Dimensions, |-11 Error Messages, I-10 VO Signals, |-9 INTRODUCTION, 2 major axes, 2 MECHANICAL UNIT, -2 MECHANICAL UNIT DESIGN SPECIFICATIONS, |-3 Memory Capacity, I-8 minor axes, -2 Multi Function Panel, 1-10 Power Requirements, I-11 RISC CPU, |-8 ROBOT CONTROLLER, |-7 ROBOT CONTROLLER DESIGN SPECIFICATIONS, |-8 Software Features, |-9 Special Features, I-10 Speed, I-8 Supplemental Data Storage, I-11 Teach Pendant, -10 Tool coordinates, |-2 Weight, I-11 Table |-1_Robot Specifications |-2_ Robot Controller versions M2 May 17, 2001UNIT 2 SAFETY UNIT 3 SWITCHES AND KEYS. UNIT 4 POWER ON/OFF PROCEDURES UNIT5 BASIC MULTI FUNCTION PANEL OPERATIONS UNIT 6 MANUAL OPERATION UNIT 7 RECORDING AND EDITING PROGRAMS UNIT 8 PROGRAM EXECUTION RY FUNCTIONS UNIT 10 ERROR CODES/HELP INFORMATION UNIT 11. OPTIONAL FUNCTONS UNIT 12 RESERVED eae ar APPENDIX ieee ee ees as eee ees aeaaes GLOSSARY INDEX eee7 :S CONTROLLER: B-—& Kawasaki Ce oe NO EOG RAMMING MANUAL OVERVIEW 1.0 OVERVIEW. 1-2 11 Major Features Of The Robot System 21-2 1.2 Major Components Of The Robot System ... 10 1.3 User Interface Devices : : ae 4.3.1 Multi Function Panel .. 18 1.3.2. SRAM PC Card..... 11-8 1.3.3. Small Teach Pendant. le 1.3.4 Controller Switch Panel 1-10 1.3.5 Personal Computer .... 1-12 1.3.6 Optional Interface Panel 1-12 14 Robot Controller Main Circuitry Overview 2113 15 C-Series Controller Digital Servo Control Overview .. 2116 1.6 Mechanical Unit Overview 1-18 May 17, 2001 1411 C SERIES CONTROLLER: g-—& Kawasaki at oe OVERVIEW 1.0 OVERVIEW 1.1. MAJOR FEATURES OF THE ROBOT SYSTEM ‘The Kawasaki F, J, and U-series robot systems consist of a mechanical unit, controller, controller software, and supporting peripheral equipment. The following major features are supported by C-series controllers: * Joint coordinate movement * Cartesian coordinate movement (Base and Too!) + Joint movement programming * Linear movement programming * Circular movement programming (optional) * Block step programming * AS language programming * Complete programming capabilities of system and program data through a user-friendly menusystem. ‘Multitasking (up to three programs) * Error message display, self diagnosis * Error and operation logging * Digital input and output intertace * Remote 1/0 (Slogic programming) * Bilingual menu + Program upload/download, editing, monitoring, etc., via personal: computer * High speed, accuracy, and load capacities due to software controlled AC servo drive system utilizing transistor PWM (pulse width modulation) and excellent mechanical unit design, 12 May 17, 20017 IES CONTR HE Kawasaki CEES Go MND pHOGRAMMMNG MANUAL OVERVIEW * High mechanical unit efficiency and smooth arm movements assured through the use of ball, needle, roller, and cross roller bearings, and spur, bevel, zerol, helical, and cycloidal gear reducers. The robot system, with proper tooling and interface, is capable of performing many tasks in the industrial environment including material handling, spot welding, arc welding, sealing, spray painting, and palletizing. 1.2 MAJOR COMPONENTS OF THE ROBOT SYSTEM The two major components of the robot system are the controller and mechanical unit. The C-series controllers are illustrated in figures 1-2 through 1-6. The F, J, and U-series me- chanical units are illustrated in figures 1-7 through 1-10. Figure 1-1 Standard C Controller Figure 1-2 C5X Controller May 17, 2001 13© SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL HE Kawasak OVERVIEW 3 iy: = LE : | Figure 1-3 European C Controller Figure 1-4 North American C Controller iS) 90 ca Figure 1-6 C80 Controller Figure 1-5 C70 Controller May 17, 2001© SERIES CONTROLLER, OPERATIONS AND PROGRAMMING MANUAL HE Kawasak OVERVIEW ae © Un Figure 1-7 FS02/03, FC02 Mechanical Units Figure 1-8 FSO6N, FS10E, FS20N, FS30L, FS45N Mechanical Units May 17, 2001 151 Cl LE mE Kawasaki GSERATIONS AND PROGRAMMING MANUAL OVERVIEW Figure 1-9 J-Series Mechanical Units Figure 1-10 UT, UX, UZ-Series Mechanical Units May 17, 20011 SERIES CONTROLLER: HE Kawasaki Ce SC aNnAING MANUAL OVERVIEW 4.3 USER INTERFACE DEVICES The user interface devices include the following: © Multifunction panel (option) * PC card (option) ‘© Small teach pendant (option) © Controller switch panel «Personal computer using KCMON or KCWIN monitor software + Optional interface panel May 17, 2001 171 ‘C SERIES CONTROLLER: BE Kawasaki ere OVERVIEW 1.3.1. MULTI FUNCTION PANEL The mult function panel, shown in figure 1-11 and 1-12, are equipped with a back light VGA color graphics LCD (liquid crystal display) touch panel, PC card slot, teach lock switch, deadman switches, and emergency stop switch. Allof the robot functions are accessible through the multifunction panel including system configuration, teaching, and program editing. In addition, an SRAM (static random access memory) PG card inserted into the multi function panel can be used for program and sys- tem configuration upload/download or system software downoad. Figure 1-11 Multi Function Panel(Type 1) Figure 1-12 Multi Function Panel(Type 2) 1.3.2. SRAM PC CARD ‘The SRAM PC card is used to upload/download programs and system configuration data, and install new AS, multifunction panel, and servo system software. PC cards are avail- able in MB, 2 MB and-4-MB capacities. The PG card utilizes batteries to maintain its memory and is not considered a permanent backup media for data. For a permanent data backup, download the contents of the PC card onto the floppy disk or hard disk of a PC. 18 May 17, 2001i C SERIES CONTROLLER: H- Kawasaki Eee OVERVIEW 1.3.3 SMALL TEACH PENDANT The small teach pendant, shown in figure 1-13, provides basic teaching and manual opera- tion capabilities for the robot, Program editing and system configuration are not acces- sible through the small teach pendant. Figure 1-13 Small Teach Pendant May 17, 2001 191 C SERIES CONTROLLER BE Kawasaki Cee OSH oC RAMMING MANUAL OVERVIEW 1.3.4 CONTROLLER SWITCH PANEL The controller switch panel, shown in figures 1-14, 1-15, 1-16, 1-17and 1-18, is composed of switches used to apply motor power, cycle start programs, hold or stop programs, select operation modes, and reset errors. An hour meter of C3X, C4X and C5X controller that indicates motor power on time, an hour meter of C1X, C70 and C80 controller that indi- cates controller power on time, a control power lamp, and error lamp are also included. The North American, European, C70 and C80 Controller switch panels are configured differently than the standard panel. The same switches are included but the hour meter and control power lamp are placed to the lett of the controller door. 0=I@OQSOOO Figure 1-14 Standard Controller Switch Panel O o & 5 Figure 1-15 North American/European _Figure 1-16 C5X Controller Switch Panel ‘Switch Panel 110 May 17, 2001HE Kawasaki C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL OVERVIEW Figure 1-17 C70 Controller Switch Panel Figure 1-18 C80 Controller Switch Panel May 17, 2001 1-111 C SERIES CONTROLLER B—& Kawasaki Ce oN NOP HOC RANBANG MANUAL OVERVIEW 1.3.5 PERSONAL COMPUTER APC (personal computer) can be linked to the C controller for program upload/download, program editing, and system monitoring. The PC requires the Kawasaki KCMON or KCWIN interface software to communicate with the robot controller. 1.3.6 OPTIONAL INTERFACE PANEL The optional interface panels are designed to interface with peripheral equipment that is connected to the robot. The interface panel is located on the robot controller door and is available in many configurations including custom designs to suit specific applications. Figure 1-19 illustrates an interface panel typically used for spot welding applications. ® © @[e@/® © OO S Qi 018 of Figure 1-19 Optional Interface Panel 1412 May 17, 20011 ;OLLER BE Kawasaki Coe OH Se RANMANG MANUAL OVERVIEW 1.4 ROBOT CONTROLLER MAIN CIRCUITRY OVERVIEW The Kawasaki C-series controller circuit board block diagram shown in figure 1-20 Illus trates the major printed circuit boards inside of the controller. The 1GA board is the main CPU (central processing unit) board in the C controller and is equipped with a 32 bit RISC (reduced instruction set computer) running at 32 MHz. This board contains the AS and servo software in FLASH memory, and user programs and system configuration data in a battery backed SRAM (static random access memory). The standard SRAM (1 MB) can be expanded to 4 MB. A super capacitor on the 1GA board provides approximately 30 minutes of memory backup when the board is removed from the card rack. When the board is reinstalled the super capacitor is recharged by the 3.6 volt lithium batteries located on the motherboard. The 1GA board is responsible for the execu- tion of the AS software, operation planning, servo position loop operations, coordinate conversions, path planning, and detection of abnormal +/- 12 VDC and +5 VDC levels. The 1GA board communicates with the servo board (1GB), power circuit control board (1FP/THP), VO boards (1FR/1GW/1HW, 1FS), optional boards for arc interface, vision, or analog input (IP), multi function panel, small teach pendant, and external equipment such as personal computer. The 1GB board is the servo CPU. The standard 1GB board is equipped with two RISCs that control six axes. The optional 1GB board is equipped with a third RISC to control a seventh robot axis and allow a conveyor input for line tracking. The 1GB board receives path data from the 1GA board, encoder data from the robot axes and conveyor, and current data from the current detect modules, to generate the PWM (pulse width modulation) signals that are sent to the IPMs (intelligent power modules) located on the power block. The IPMs in turn allow current to flow through the three phase servo motor windings and produce motor rotation. A 1GM board is attached to the 1GB board to provide an interface for the current sensors. In addition, the 1GB board also controls servo motor brake func- tions, overtravel limit switch signal processing, and servo system error processing. The 1GC or 1GD board is the servo system power block. The 1GC board is used for robots with payload capacities of 30 kg or more and the 1GD board is used for robots with lower than 30 kg payload capacities. The power block is comprised of two sections: the power unit and the amplifier. The power unit section rectifies and filters three phase AC power for use by the servo motors, monitors DC voltage levels, controls regenerative voltage levels, and reports voltage level and regenerative resistor circuit errors. The ampli- fier section receives PWM signals from the 1GB board. The PWM signals are used by the —__ PMs to control current flow through the servo motor windings. Current detect modules are used to send current level data back to the 1GB board to indicate robot load. The amplifier section also incorporates various protective functions that are monitored by the 1GB board. May 17, 2001 1-431 C SERIES CONTROLLER B-E Kawasaki ier rere OVERVIEW The 1FP/1HP board controls the power up sequence of the controller and serial communi- cation for the multi function panel/small teach pendant and 1GA/1GB board. In addition, the 1FP/1HP board will power the controller down if an abnormality of the +/-12 VDC, +5 VDC, or 24 VDC levels exists. The 1FR/1GW/HW board is a parallel /O board providing 32 input channels and 32 output channels including dedicated signals. Up to four 1FR boards can be installed in the C controller for a total of 96 inputs and outputs. The 1FS board (optional) is available in two versions: R/IO and RS485 communication or Control-Net communication. The board is equipped with a 32 bit RISC running at 20 MHz and 2 MB or 4 MB of FLASH memory for software/Slogic program storage. The RVO version 1FS board can be configured as a remote rack of a PLC and provides serial PLC and weld timer communication 114 May 17, 2001HE Kawasaki (MULTI FUNCTION PANEL =n) {COLOR 3] (roucs paxeD (Pccano READER) RISC [powrs 2.3] uowrs 5.6) a (R50) [ENCODER || ENCODER cSERI OVERVIEW io xs] ‘won {FUNCTION PANEL] (VOLTAGE WONTORING Moster Bowe VME BU [Ream] [FFs OPTION 1 | |vorexavs| | |ReMoTE | @ om, conve (aise) [ENCODERTE [BRAKE CONTRO SEQUENCE (om T SC tees) 160 (sat) 2m) — [courRoe Net [ARC ES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL ‘CONTROL PANEL SWrTeHEs 6 S| sete Cc J [oPTON PCBS) (sion) enconer Figure 1-20 Circuit Board Block Diagram May 17, 2001 1-151 C SERIES CONTROLLER: g-& Kawasaki See eee OVERVIEW 1.5 C-SERIES CONTROLLER DIGITAL SERVO CONTROL OVERVIEW Because a complete discussion of the digital servo drive system is beyond the scope of this text, the servo drive circuitry will only be discussed in general terms here. Figure 1-21 provides a block diagram of the servo amplifier. There are four major components in the C controller servo drive system: * Power block assembly * 1GB board and servo software * AC servo motor assembly * Hybrid encoder assembly The 1GB board receives path data from the 1GA board, encoder data from the robot axes and conveyor, and load data from the current detect modules. The servo software uses these signals to calculate and produce an all digital command signal. The command signal is combined with a triangular wave reference signal to determine the sampling rate of the ‘command signal and to generate the PWM (pulse width modulation) signals that are sent to the IPMs (intelligent power modules) located on the power block, ‘APWN signal is a pulsed signal with a width or duration that is changed proportionally to motor demands. In other words, the duty cycle of the servo motor is changed in relation to the width of these drive signals. For example, during motor startup from a stopped condi- tion, the width of the PWM signals would be quite wide in comparison to the PWM signals required when the motor reaches its sustained velocity. The power block is comprised of two sections: the power unit and the amplifier. The power unit receives 210 VAC/60Hz input power from the main transformer assembly. This voltage is filtered and rectified to provide 300 VDC to the IPMs. The amplifier section receives the PWM signals from the 1GB board. The PWM signals are used by the IPMs to control current flow through the servo motor windings. The IPMs are arranged in pairs, with each pair connected to a specific motor winding. When the IPMs are gated by the PWM signals, current will low through the U, V, and W phases of the AC servo motor causing motor rotation, ‘Current detect modules located on the power block provide feedback to indicate the cur-__ ~ tent levels of the U and V phases. Signals from the modules are sent to the 1GB board where they are used to calculate the W phase current, determine torque requirements, and detect overcurrent errors and current limiter conditions that could damage the servo motor and power block. The hybrid encoder assembly is mounted to the end of the servo motor and coupled to the servo motor shaft. Its function is to sense the servo motor shaft position, direction of rota- 1416 May 17, 2001H-~E Kawasaki Cee Oe SS aaumuNG MANUAL OVERVIEW tion, and velocity. This data is sent to the 1GB board for phase calculation and processing by the software position and velocity loop amplifiers. sEAVO MOTOR Sea “A rat eB | ria | eee NCODER SIGNAL, $< JURRENT FEEDBACK < 10 eoano Figure 1-21 Servo Amplifier Block Diagram May 17, 2001 177 C SERIES CONTROL B-~E Kawasaki See OLE nina HAMA OVERVIEW 1.6 MECHANICAL UNIT OVERVIEW The mechanical unit consists of the arms, linkages, and drive components necessary to provide smooth, accurate, and repeatable movement for consistent teaching and program playback, The typical mechanical unit provides six axes of motion and is available in a variety of configurations that are suited for numerous applications under a variety of condi- tions. Table 1-1 lists the basic drive components of the robot axes Table 1-1 Drive Mechanisms ROBOT DRIVE MECHANISMS JCS/JS5/JW5S JS10 JS30/40 UT/UX/UZ CYCLOIDAL | CYCLOIDAL |ROTA-VECTOR] HELICAL Jv4 REDUCTION | REDUCTION | REDUCTION | GEARS UNIT UNIT UNIT CYCLOIDAL | CYCLOIDAL |ROTA-VECTOR] CYCLOIDAL JT2 REDUCTION | REDUCTION | REDUCTION | REDUCTION UNIT UNIT UNIT UNIT CYCLOIDAL | CYCLOIDAL [ROTA-VECTOR] CYCLOIDAL JTS REDUCTION | REDUCTION | REDUCTION | REDUCTION UNIT UNIT UNIT UNIT CYCLOIDAL | CYCLOIDAL REDUCTION | REDUCTION JT4 SPUR GEARS | SPUR GEARS UNIT, UNIT, SPUR GEARS | SPUR GEARS CYCLOIDAL | CYCLOIDAL REDUCTION | REDUCTION SPUR GEARS, |SPUR GEARS, | °° Gy. UNIT, JTS IZEROL GEARS|BEVEL GEARS SPUR GEARS, |SPUR GEARS, BEVEL GEARS |BEVEL GEARS. CYCLOIDAL—|-CYCLOIDAL REDUCTION | REDUCTION ume | SEUR GEARS. [SPUR GEARS | _UNIT, UNIT, SPUR GEARS, |BEVEL GEARS, | BEVEL GEARS | SPUR GEARS 118 May 17, 2001H-~E Kawasak © SERIES CONTROLLER, OPERATIONS AND PROGRAMMING MANUAL OVERVIEW Table 1-1 Drive Mechanisms(Continued) ROBOT DRIVE MECHANISMS Fs02/03 | Fsoewrstoe/Fszon| FS30L/FS45N cYCLOIDAL | ROTA-VECTOR wm HARMONIC | REDUCTION | REDUCTION UNIT UNIT CYCLOIDAL ROTA-VECTOR JT2 HARMONIC | REDUCTION | REDUCTION UNIT UNIT cyc.oipat | ROTA-VECTOR JT3 HARMON'C | REDUCTION | REDUCTION UNIT UNIT HaRMoNic | ROTA-VECTOR Jv4 SPUR GEARS DRIVE, REDUCTION SPUR GEARS UNIT, SPUR GEARS HARMONIC ROTA-VECTOR i DRIVE, eee REDUCTION SPUR GEARS.| MING BELT | iyo BELT BEVEL GEARS| TIMING BI Harmonic | HARMONIC | ROTAWECTOR a DRIVE, DRIVE, UNG SPUR GEARS,| TIMING BELT, | evi NGears BEVEL GEARS| BEVEL GEARS | SSR crane” May 17, 2001 1419© SERIES CONTROLLER. OPERATIONS AND PROGRAMMING MANUAL BE Kawasaki OVERVIEW 1FR/1GW/HW board major components 4-14 1-3 1FP/HP board mechanical unit 1-14 1-19 1FS board multifunction panel 4-14 18 1GA board parallel VO 1-14 114 1GB board PC card 1-13, 146 1-8 1GC board personal computer 1-13 1:12 1GD board PLO 1-13 1-13 1GM board power block 1-13 4-13, 1-16 amplifier power unit 1-16 1-16 central processing unit power up sequence 1-13 114 Current detect modules pulse width modulation 1-16 1-13 digital command signal PWM 1-16 1-13, 116 efficiency, mechanical unit RUO version 1-3 1-14 FLASH memory RISC 1-13 1-13 Hybrid encoder serial communication 1-16 1-13 hybrid encoder assembly servo CPU 1-16 1-13 intelligent power modules servo motor 1-13 1-16 interface devices servo software 1-7 1-16 interface panels, interface ‘small teach pendant 4 1-9 IPM SRAM 1-43 1-13 lithium batteries switch panel 1-13 111 main CPU weld timer 1-43 1-14 1-20 May 17, 2001i C SERIES CONTROLLER B-~& Kawasaki GenrONsneroce aes acess OVERVIEW Figure 1-1 indar ntroller Figure 1-2_C5X Controller Fi = in ntroller Figure 1-4 North American C Controller Figure 1-5 C70 Controller Figure 1- ntroller Figure 1-7 FS02/03, FC02 Mechanical Units re 1-8 F: FS10E, FS20N, FS30L, FS4! hanical Unit: Fig re 1-21 Serv rvo Amplifier Block Diagram Table 1-1 Drive Mechanisms May 17, 2001 1-21UNIT 1 OVERVIEW UNIT 3 SWITCHES AND KEYS ——E UNIT 4. POWER ON/OFF PROCEDURES a UNIT 5 BASIC MULTI FUNCTION PANEL OPERATIONS UNIT 6 MANUAL OPERATION UNIT 7 RECORDING AND EDITING PROGRAMS UNIT 8 PROGRAM EXECUTION UNIT 9 AUXILIARY FUNCTIONS UNIT 10 ERROR CODES/HELP INFORMATION a ee UNIT 11. OPTIONAL FUNCTONS UNIT 12 RESERVED APPENDI \ a GLOSSARY INDEX QS' 2OLLER BE Kawasaki SSS UTON GN eIoee esses 2.0 24 22 2.2.1 2214 221.2 2.2.1.3 22.1.4 2.2.2 2.2.3 SAFETY SAFETY... Introduction oon Personal Safety ... Personnel Safety Categories Personal Safely .. Safety During Operation ... Safety During Programming Safety During Inspection And Maintenance Safety Features ... Work Envelope Drawings May 17, 2001 a1 C SERIES CONTROLLER g—& Kawasaki oe een SAFETY 2.0 SAFETY 2.1 INTRODUCTION Safety is an important consideration in the use of automated and robotic equipment in the industrial environment. All operators, maintenance personnel, and programmers must be aware of all automated equipment, peripheral and robotic equipment that occupies the work cell, and their associated operational and maintenance procedures. For this reason it is recommended that all personnel who operate, maintain, and program Kawasaki robots, attend a Kawasaki approved training course that would be pertinent to each employee's specific job responsibilities. The following safety sections in this text are designed to support and augment existing safety guidelines that may be in use in your plant, and/or are provided by municipal, state, or country, but are NOT designed to supplant or supersede any existing rules, regulations, or guidelines that may be in use. Because safety is the primary responsibility of the user, owner, and/or employer, Kawasaki recommends that specific safety guidelines and recom- mendations be adopted from groups or individuals that are professionals in safety design and implementation. All safety related issues and descriptions, either presented in written or oral form from any representative of Kawasaki, Inc., are intended to provide general safety precautions and procedures and, therefore, are not intended to provide all safety measures necessary for the protection of all personnel in the work environment. Kawasaki robots are considered safe for use in industrial environments when all safety guidelines are adhered to. Adherence to the safety guidelines for safe robot operation and the protection of personnel and equipments the responsibility of the end user. 22 May 17, 2001HE Kawasaki eERATIONS AND PROGRAMMING MANUAL SAFETY 2.2 PERSONAL SAFETY 2.2.1. PERSONNEL SAFETY CATEGORIES Personnel safety can be described in one of four categories: ‘* Personal safety + Safety during operation * Safety during programming ‘+ Safety during inspection and maintenance A description of each follows in this section. 2.2.1.1 PERSONAL SAFETY Safety procedures must be an integral part of operational procedures for the operator, programmer, and maintenance person. These procedures must be followed explicitly and ona regular basis. If consistent safety procedures are followed on a daily basis, they should become a regular part of everyday operational procedures which are designed to protect the user. Some guidelines are presented in brief in the following section: * Before operating or maintaining the robot or robot controller, be sure you fully under- stand and comprehend all maintenance, operating and programming procedures, and ensure that all safety related precautions are taken and complied with before these procedures are attempted. ‘* Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry when working ‘on the controller and robot. Its also recommended that if ties must be worn in your shop environment, that they be the clip-on variety, rather than tied ties. ‘* Always wear safety glasses or goggles and approved safety shoes for your shop condi- tions, Follow all applicable local, state, country, and plant safety specifications and procedures. —_——*—Knew the entire work cell or area that the robot occupies. * Be aware of the entire work envelope of the robot and any peripheral devices. * Locate all emergency stop buttons or switches. May 17, 2001 231 c :§ CONTROLLER HE Kawasaki OA nS AND OHOGRAMMING MANUAL SAFETY * Avoid trap points in which personnel could become trapped between a moving device and any stationary devices. * Personnel should never enter the work envelope during automatic operations. + Ensure that all personnel are clear of the work envelope before initiating any motion commands for the robot, * Before initiating any motion commands, KNOW beforehand how the robot will perform when that commands given. * Be sure that the entire work area is free of any debris, tools, fixturing, lubricants, and cleaning equipment before operation of the robot is attempted. * Ifany personnel observe unsafe working conditions, report them immediately to your supervisor or plant safety coordinator. © Allpersonnel should identify by name and function all switches, indicators, and control signals that could initiate robot motion. * Never defeat, render useless, jumper out, or bypass any safety related device, whether mechanical or electrical in design. * Allsafety devices approved for use in your plant must be properly installed and main- tained to ensure personnel safety. ‘* NEVER attempt to stop or brake the robot during operation with your body or person. Utilize Emergency-Stops only to stop robot motion. 2-4 May 17, 20011 c B-— Kawasaki Cae GS IND HOGRAMMING MANUAL SAFETY 2.2.1.2 SAFETY DURING OPERATION ‘© During operation of the robot, identify the maximum reach of the robot in all directions, which is referred to as the work envelope. * Always keep your work area clean and free of any debris which includes, but is not limited to, oil, water, tool, fixturing, electronic test equipment, etc. ‘© During operations that involve the teach pendant, the only person allowed in the work envelope is the teacher, or the person operating the teach pendant. The teach pendant has provisions to protect the operator. These safety provisions include an Emergency- Stop, trigger switch, and deadman switch. * Never block the operator's path of retreat. * During the teach operation of the robot always have a path of retreat planned. + AVOID pinch points. May 17, 2001 25i C SERIES CONTROLLER: B-& Kawasaki ener a SAFETY 2.2.1.3 SAFETY DURING PROGRAMMING * During operation of the robot, be sure you are able to identify the maximum reach of the robot in all directions, which is referred to as the work envelope. © During teach operations the only person allowed in the work envelope is the teacher, or the person operating the teach pendant. The teach pendant has provisions to protect the operator including Emergency-Stop, trigger switch, and deadman switch. ‘+ AVOID pinch points. © During point-to-point playback operations, be aware that the robot is only cognizant of its present location and the next point itis requested to move to. It will execute this move with total disregard to what may lie in its path when the move is executed ‘* Playback accuracy and speed can affect the geometry of the path coordinates. There- fore, when changing accuracy or speed, always test run the program at a slow speed, or point-to-point mode before attempting the continuous path operation in the repeat mode. ‘* ALWAYS test run a new path program at a reduced speed, or in point-to-point mode prior to attempting a high-speed playback operation in the repeat mode. 26 May 17, 20011 SERIES CONTROLLER B—& Kawasaki CEE OE LE anAnGHANUAL SAFETY 2. 4 SAFETY DURING INSPECTION AND MAINTENANCE Before entering the work envelope to perform either inspection or maintenance proce- dures, tum off three-phase power on the disconnect and tag, and lock-out the disconnect switch. A WARNING The input side (top) of the controller disconnect may stil be live when the controller disconnect is turned OFF. If work is to be performed at the controller disconnect switch, tur OFF the three phase power at the source, and tag and lock-out the source disconnect. * When removing an axis motor, be aware that the axis wil fall if left unsupported. The brake assembly is in the servo drive motor, therefore, the axis of the robot will be unsup- ported if removed * When using the axis brake release switches in the controller, be aware that the axis may fall ifleft unsupported. * Before working on pneumatic or high pressure water supplies, turn off supply pressure and purge all lines to remove any residual pressure. * Assign only qualified personnel to perform all maintenance procedures. * Consult all available documentation before attempting any repair or service procedures. * Use only replacement parts approved by Kawasaki Before attempting to.adjust or repair-a device in the robot controller. that may have yellow interlock control circuit wires attached, locate the source of the power and re- move it by disconnecting the appropriate disconnect at its source. * During inspection and maintenance procedures, if your installation is equipped with safety fences and safety plugs, remove and hold the safety plug while performing these operations. In addition, the safety procedures outlined above should be adhered to. May 17, 2001 271 C SERIES CONTROLLER: B-E Kawasaki See ee nan SAFETY 2.2.2, SAFETY FEATURES To safeguard the user, the Kawasaki robot system is equipped with many safety features. Some of these safety items include: * All Emergency-Stops are hardwired. + The Multi Function Panel, the Teach Pendant, and Operation Panel are all equipped with red mushroom Emergency-Stop push buttons. * Robot velocities are constantly monitored by software. Should an over-velocity condi- tion be detected, the robot will fault in a velocity error condition. * Teach velocities and check mode velocities are limited to a maximum of 250 mm/sec. * Allrobot axes have software limits. * All J-series mechanical units have overtravel hardstops on JT1 and JT2. All U-series mechanical units have overtravel hardstops on the JT1, JT2, JT3, and JT5 axes. * All robot axes are monitored by the robot controller for velocity and deviation errors. * Allrobot axes are equipped with 24 VDC electromechanical brakes. Should the robot lose line power, the robot arm will not drop because the brakes are engaged when power is off at the robot controller. 28 May 17, 2001H-~E Kawasaki OPERATIONS AND PROGRAMMING MANUAL SAFETY 2.2.3: WORK ENVELOPE DRAWINGS Figure 2-1 FS02/03, FC02 Work Envelope May 17, 2001 291 (OLLER B-—E Kawasaki OPERATIONS AND PROGRAMMING MANUAL SAFETY Figure 2-2 FSO6N Work Envelope 240 May 17, 2001© SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL SAFETY Figure 2-3 FS10E Work Envelope May 17, 2001 anB—& Kawasaki Sean ar SAFETY x 3600 t v= : we Bot a a $2 1253, 2073 oe Figure 2-4 FS20N Work Envelope 2412 May 17, 2001i C SERIES CONTROLLER Bi -& Kawasaki Ce one iG MANUAL SAFETY 570 3052 Figure 2-5 FS30L Work Envelope May 17, 2001 2413' SONTROLL B-~E Kawasaki Cee ew mNaMANUAL SAFETY Figure 2-6 FS45N Work Envelope 214 May 17, 2001| ~ Kawa saki C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL SAFETY Figure 2-7 JAS/JC5/JS5/JWS5 Work Envelope May 17, 2001 215BE Kawasaki CSEmEs CONTROLLER OPERATIONS AND PROGRAMMING MANUAL. SAFETY Figure 2-8 JA10/JS10 Work Envelope 2416 May 17, 20011 C SERIES CONTROLLER: @-& Kawasaki Sereno anita SAFETY Fuie Eye volte IG: 720" a at ‘OGrT 062 ‘008 Figure 2-9 JS30 Work Envelope May 17, 2001 2171 St ‘Cor ER Bi -& Kawasaki SEO Nae EAMG MANUAL SAFETY MiB Eye DOltS TB: 7201 eee: " oore Svea] Figure 2-10 JS40 Work Envelope 218 May 17, 20011 C SERIES CONTROLLER Hi -& Kawasaki SremTOne NO RDON Ede aL SAFETY C=) — bel Figure 2-11 UT-Series Work Envelope May 17, 2001 2191 C SERIES CONTROLLER: B-~& Kawasaki GeERATIONS AND PHOCRANAAING MANUAL SAFETY Figure 2-12 UX70 Work Envelope 2-20 May 17, 2001| i ~< Kawasaki C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL, SAFETY | Figure 2-13 UX100/120/150 Work Envelope May 17, 2001 2211 C SERIES CONTROLLER H-~E Kawasaki CARS In eS RAMMING MANUAL SAFETY 2a. IN Figure 2-14 UX200 Work Envelope 2-22 May 17, 20011 C SERIES CONTROLLER: BE Kawasaki ce ie emer SAFETY Figure 2-15 UZ100/200/150 Work Envelope May 17, 2001 2-231 SERIES CONTROLLER mE Kawasaki Rooters renee SAFETY JA10/JS10 work envelope, 2-16 JABISC5ISSS/JWS work envelope, 2-15 JS30 work envelope, 2-17 JS40 work envelope, 2-18 F'S02/03, FC02 work envelope, 2-9 FSO6N work envelope, 2-10 FS10E work envelope, 2-11 FS20N work envelope, 2-12 FS30L work envelope, 2-13 FS45N work envelope, 2-14 Personal safety, 2-3 Personnel safety categories, 2-3, Safety, 22 Safety during inspection and maintenance, 2-7 Safety during operation, 2-5 Safety during programming, 2-6 Safety features, 2-8 Trap points, 2-3, UT-series work envelope, 2-19 UX100/120/150 work envelope, 2-21 UX200 work envelope, 2-22 UX70 work envelope, 2-20 UZ100/120/150 work envelope, 2-23 Work cell, 2-3 Work envelope, 2-3 Work envelope drawings, 2-9 Figure 2-1 FS02/03. FC02 Work Envelope Figure 2-2 FSO6N Work Envelope Figure 2-3 FS10E Work Envelope Figure 2-4 FS20N Work Envelope Figure 2-5 FS30L Work Envelope Figure 2-6 FS45N Work Envelope Figure 2-7 JAS/JC5/JS5/JW5 Work Envelope Figure 2-8 A10/JS10 Work Envelope Figure 2-9 JS30 Work Envelope i 10 -JS40 Work-Envel Figure 2-14 -Series Work Envelope Figure 2-12 UX70 Work Envelope Figure 2-13 UX100/120/150 Work Envelope Figure 2-14 UX200 Work Envelope Figure 2-15 UZ100/120/150 Work Envelope 2-24 May 17, 2001UNIT 1 OVERVIEW { UNIT 2 SAFETY UNIT 4 POWER ON/OFF PROCEDURES, UNIT 5 BASIC MULTI FUNCTION PANEL OPERATIONS. UNIT 6 MANUAL OPERATION UNIT 7 RECORDING AND EDITING PROGRAMS UNIT 8 PROGRAM EXECUTION UNIT 9 AUXILIARY FUNCTIONS. UNIT 10 ERROR CODES/HELP INFORMATION UNIT 11. OPTIONAL FUNCTONS UNIT 12 RESERVED ee APPENDIX GLOSSARY INDEXHy C SERIES CONTROLLER B-~E Kawasaki GPeraT ONG DRAG! etn en 3.0 34 3.1.1 3.2.4 3.2.2 3.2.3 3.2.3.1 3.2.3.2 3.2.3.3 3.2.3.4 3.2.3.5 3.2.3.6 3.2.3.7 3.2.3.8 3.2.3.9 3.2.3.10 3.2.3.1 SWITCHES AND KEYS SWITCHES AND KEYS Controller Control Panel Switches Multi Function Pane... Multi Function Panel Description . Multi Function Panel Display Areas ... Multi Function Panel Touch Keys Program And Step Selection Keys Screen Selection Keys . : Selection Keys For Auxiliam Program Data... Clamp And Signal Selection Keys ..... x (Output External) And Wx (Wait External) Selection Keys . Record And Teach New Keys : ‘Aux Set & Disp Key SKY vere Check Mode Keys. Robot Manual Operation Keys... Keyboard ... May 17, 2001 341 C SERIES CONTROLLER BE Kawasaki Geers ONG MID PHOG ain HA SWITCHES AND KEYS 3.0 SWITCHES AND KEYS This unit provides information about the switches and keys located on the main body of the controller, multi function panel, and keyboard. 3.1 CONTROLLER The C-series controller is available in four versions; standard, North American, European, C5X, C70 and C80 Controller. The controllers are shown in figures 3-1, 3-2, 3-3, 3-4 and 3-5 respectively. Mutt Funetion Panel (option) 2 (Type 1) (4) ~ Samal — (7) (3) — oh Hy — 8) mn } @ (6) @) — © Teach Pendant or ‘Mutti Function Panel Connector Circuit Breaker Power Cable Opening 15-2320 Frame tor Castor Assistant Connector Figure 3-1 Standard C Controller 32 May 17, 2001HE Kawasaki C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL SWITCHES AND KEYS 2 er ~~ Multi Function Panel (Type 1) Disconnect Switch — WF Switch Panel — 2 arrow o RS-232C Connector AC Outlet TIP Connector F Figure 3-2 North American C Controller May 17, 2001 33T C SERIES CONTROLLER Hi - Kawasaki CASTERS NESS mana MANUAL SWITCHES AND KEYS ga o a —— sum eunction Panel U [ | (Types) J ie UF Switch Panel ——— 2 anrowo RS-232C Connector AC Outlet TIP Connector Disconnect Switch ——— a | oo ] =“ Door Lock ——— | La Figure 3-3 European C Controller 3-4 May 17, 2001BE Kawasaki SWITCHES AND KEYS 2 Disconnect Switch —} ac outlet Floppy Disk Drive Unit: Be ® 509) © SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL, Multi Function Panel(Type 2) (Option) Figure 3-4 C5X Controller @ Noe oro + RS-232C Connector ‘VP Connector May 17, 2001 35© SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL. B- Kawasak SWITCHES AND KEYS Multi Function Panel (Type 1) RS-232C Connector Break Release = Unit Connector Floppy Disk Drive Unit TIP Connector DisConnect Switch Figure 3-5 C70 Controller 36 May 17, 20011 C SERIES CONTROLLER B—& Kawasaki CE IND gAORAMANG MANUAL SWITCHES AND KEYS T/P Connector = 1-9 tC | 3 |—4 : ; lg Disconnect 7 * } | switch posts Te Switch i Panel Door Lock Accessory * Floppy Disk Drive : Multi Function Unit Panel(Type 2) + RS-232C Figure 3-6 C80 Controller May 17, 2001 37BE Kawasak C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL ‘SWITCHES AND KEYS 3.1.1 CONTROL PANEL SWITCHES The control panel switches are located on the controller door and provide control for the basic robot operations. The function of these components is described in table 3-1. Table 3-1 Control Panel Switches No. ‘Switch&Lamp 1x, 02x, 670, C80 CX, 4x, 5x. Function Indicates that the controller power supply is turned ON, Indicates the total controller power ON time.(C1X,C70, controller) Indicates the total motor power ON time.(C3X, C4X, CSX controller) Indicates that an error has occurred. When the iniial- ization screen appears, this lamp blinks. He When this switch is pressed, the error is reset and the 4 error lamp is turned off. (When the error occurs continuously, this switch will not clear the error) If this switch is pressed when the initialization screen apears, the controller is not initialized. @ | s® ‘The RUN position allows program execution and robot motion; the HOLD position places the robot into a temporary stop condition. ‘TEACH REPEAT Selects the teach or repeat mode of operation. 38 May 17, 20011 SERIES Ct A BE Kawasaki Cee ee aan MANUAL SWITCHES AND KEYS Table 3-1 Control Panel Switches (Continued) No. Switch&Lamp Function CHK, OK, 70, C80 9X, C4X, 05% eveaggamt When the CYCLE START switch is pressed, the 7 i selected program begins execution. The lamp lights, during program execution. worogzoven . When the MOTOR POWER switch is pressed, motor 8 = power is turned ON. The lamp lights while motor power is ON. a When the EMERGENCY STOP switch is pressed ; motor power is turned OFF, the brakes are applied, and the robot stops. The motor power lamp and cycle start lamp are turned OFF at this time. May 17, 2001 39i IES CONTROLLER HE Kawasaki CSE Sonne PROGRAMMING MANUAL ‘SWITCHES AND KEYS 3.2 MULTI FUNCTION PANEL 3.2.1 MULTI FUNCTION PANEL DESCRIPTION The multi function panel shown in figure 3-7 and 3-8, is equipped with VGA color LCD (liquid crystal display) touch panel, a pen to operate the touch panel keys, a PC card slot, and various switches. The function of these components is described in table 3-2 and 3-3. Figure 3-7 Multi Function Panel(Type 1) NOTE: Ifthe LCD display screen of the multi function panel is exposed to high levels of static electricity, the display may go blank for a short period. The display will show the open- ing screen when the static electricity has dissipated. This condition will not cause an error message. 3-10 May 17, 20017 =S CONTR HE Kawasaki Cee ee aan HANUAL SWITCHES AND KEYS Table 3-2 Multi Function Panel(Type 1) No| Switch Function evenconer stor | When the EMERGENCY STOP switch is pressed motor power is 1 turned OFF, the brakes are applied and the robot stops. The motor power lamp and cycle start lamp are turned OFF at this time. onorr | Teach lock ON - cycle start (program execution) is disabled; teach- 2 ing, jogging, and check mode operations can be performed. TEACH LOCK Teach lock OFF - cycle start is enabled; teaching, jogging, and check mode operations cannot be performed. 3 | Trigger switch | One of the two trigger switches must be pressed to enable motor power in the teach mode and check mode. 4| Liquid crystal | Provides touch keys for teaching, editing, check mode operations, display and configuring and monitoring the robot system. Also provides display areas for system status, error messages, program data, system data, etc. 51 PCcardslot | Opening to insert a PC card for backing-up or restoring data in the controller memory. 6| Contrast | Adjusts the brightness of the LCD backlight, adjustment 7| Touch panel pen| Pen used for operation of the keys on the touch screen. May 17, 2001 341i ‘TF HE Kawasaki Cee ONS HOCRAMMNG MANUAL SWITCHES AND KEYS 8 as —10 7— gaa )%—1 sae Bh 3 ean 14 (Rear side) | : 15: | (Rear side) 16 (17 Figure 3-8 Multi Function Panel(Type 2) NOTE: If the LOD display screen of the multifunction panel is exposed to high levels of static electricity, the display may go blank for a short period. The display will show the open- ing screen when the static electricity has dissipated. This condition will not cause an error message. 3-12 May 17, 2001Hy EF HE Kawasaki GpERATIONS AND PROGRAMMING MANUAL SWITCHES AND KEYS Table 3-3 Multi Function Panel(Type 2) Ne ‘Switch Function BERGE STOP | @ When the EMERGENCY STOP switch is pressed motor power is turned OFF, the brakes are applied and the robot stops. The motor} power lamp and cycle start lamp are turned OFF at this time. as) AGH LOCK a Teach lock ON - cycle start (program execution) is disabled; teach- ing, jogging, and check mode operations can be performed. Teach lock OFF - cycle start is enabled; teaching, jogging, and check mode operations cannot be performed. 3 | Trigger switch One of the two trigger switches must be pressed to enable motor power in the teach mode and check mode. 4] Liquid crystal display Provides touch keys for teaching, editing, check mode operations, and configuring and monitoring the robot system. Also provides display areas for system status, error messages, program data, system data, etc. 5] PC card slot Opening to insert a PC card for backing-up or restoring data in the controller memory. 6| Contrast adjustment ‘Adjusts the brightness of the LCD backlight Use by using together about the CLAMP(CL1. ,CL2) key and the RECORD(REC) key, etc. (Option) 8 oO SHIFT Use together with AXIS Key when you operate auxiliary axis such as External axes. Operate the SHIFT(LED is in the state of lighting up) key and C= os key about Servo Welding Gurraxis However, there is a case which becomes keys other than the fi —N operated ( -) x pas at the case Traverse axis and two| or more Servo Welding Gun are connected, too May 17, 2001 3413, JX : —1 st ;OLLER: B-—E Kawasaki Cee LES aanGMANUAL SWITCHES AND KEYS Table 3-3 Multi Function Panel(Type 2) Continued No] _ Switch Function (e Select the motion coordinate system of the manual operation 9 te (Teach mode operation). : ->JOINT > BASE > TOOL-> Use this key when you change the operation speed of the manual 10 operation speed and the check mode axis. The speed change whenever you presses this key. 1 Use this key when you change mode of the check mode motion. ->ONCE -> CONTINUE -> Itlight up LED of this key at CONT mode. 12 (] 1 Atthe teaching, use this key when the motion of the robot by xX manual. © ee 13 Ifyou press this key while pressing TRIGGER Switch, the motion of the robot toward the displayed step. When you release this key, the robot will stop. When “Check ONCE" has been selected, robot eck will be stop the axis coincided at the taught point. 14 CHECK When you press this key while pressing TRIGGER Switch, the motion of the robot toward the previous step of the displayed step. When you release this key, the robot will stop. Regardless of “Check ONCE" and “Check CONTINUE", robot will be stop the axis coincided at the taught point. 344 May 17, 20011 CSERI IOLLER HE Kawasak See Ones CmanG MANUAL SWITCHES AND KEYS Table 3-3 Multi Function Panel(Type 2) Continued No} — Switch Function /@ Use this key when you call Interface Panel Screen. (Only the case where interface Screen is registered by the controller is a valid.) (Option) Interface Screen- and Interface Screen-2 change whenever you press this key. REC ae) =a sof Use this key when you record teach data and current position in a present step according to teaching mode. However, in this key, Black step of TEACHING Screen or AS INSTRUCTION TEACH- ING and AS INSTRUCTION TEACHIG Screen is displayed and only the state of pressing the ENA key is a valid (Ifyou does not press the ENA key, the record is not done even if you press this key.) 17 Use this key when you set the Clamp signal. However, you can use only the state to press the ENA key. (The operation of the ENA key and simultaneous is an option.) (It cannot set the Clamp signal by pressing this CL key at the case you does not press the ENA key.) May 17,2001 3-15' CONTROLLER BE Kawasaki SeeineNe Me och adie Wi SWITCHES AND KEYS 3.2.2 MULTI FUNCTION PANEL DISPLAY AREAS The display of the multifunction panel will normally appear as shown in figure 3-9. Its appearance will vary as the touch panel keys are pressed to display menus, system and program information, etc. The various areas of the display are described below. If the multi function panel display is not touched for a period of ten minutes, the display will automati- cally go to a dark screen saver mode. Touching any area of the display screen when itis in this mode will reactivate the colored display. Teaching Screen Auxiliary information Statusarea Displaying area i RE D> | ssese sone un System mac . . messaages eer mer 32 roe 8 Title area ¢ Cur OFF ofr seo 209 Bex 00 o09 mec e suMe exo ex Auxiliary ii ae Pose | Parl Figure 3-9 Multi Function Panel Display * System message area -This area is reserved for robot system errors, operational errors, messages from Slogic instructions or the AS language print or type commands. * Title area : This area displays the title of the selected screen or menu item, for ex- ample, STATUS, AUX, etc. © Auxiliary data area : This area displays the auxiliary data that will be used for teaching the robot. * STATUS area : This area displays various conditions of the robot system as shown in figure 3-10. Motor power ON/OFF (M-ON/M-OFF), hold/run conditions, repeavteach modes, slow repeat and wait conditions, and spray ON/spray inhibit (paint application only) conditions are displayed. 3-16 May 17, 20011 C SERIES CONTROLLER HE Kawasaki CSE OMe eHOGRANMING MANUAL SWITCHES AND KEYS joMorF | [OM-ON joHoLD | JORUN joTEAcH | OWAIT REPEAT SLOWREPEAT lo © SPRAY ON SPRAY INHIBIT Figure 3-10 Robot System Conditions ‘* Teaching Screen Auxiliary information Displaying area (option) When the current selection step is a step of Black step, Auxiliary information is dis played. Nothing is displayed for the step of the AS instruction. You set “Teaching Screen Auxiliary information displaying’ function in “EFFECT” by “Auxiliary 96 ENVIRONMENT DATA OF PANEL”. And, when TRIGGER Switch is “OFF”, this Screen is displayed. CURRENT: Itis temporary data while setting the Auxiliary data. MEMORY: Itis teached data of the current program step. * The speed is displayed at direct speed specification. «The data of over CLAMP 3 is not displayed on this screen. * When OX and WX signals 6 or more are taught, the lasts sign number is added to * mark. 3.2.3 MULTI FUNCTION PANEL TOUCH KEYS 3.2.3.1 PROGRAM AND STEP SELECTION KEYS = Pe The keys shown above are used to select robot programs, PC programs, program steps, and display the selected program name and step number. The function of these keys is described in table 3-4. May 17, 2001 3-17i C SERIES CONTROLLER: BE Kawasaki Cee OARS eaNMING MANUAL SWITCHES AND KEYS Table 3-4 Function of Program and Step Selection Keys Function The PROGRAM key displays the currently selected program. When this key is pressed the program select screen appears, and another program can be selected The STEP key displays the currently selected program step. When this key is pressed the step selection screen appears, and another program step can be selected. The PC key displays the currently selected PC program 3.2.3.2 SCREEN SELECTION KEYS The keys shown above are used to select teaching methods, auxiliary menus, robot status screens, and the keyboard screen. The function of these keys is described in table 3-5. Table 3-5 Function of Screen Selection Keys Key Function ea The TEACHING key toggles between block step programming and AS language programming modes. liesd i ‘STATUS, When the status screen is selected by the NEXT MENU key, the STATUS ke} toggles between the status screen, program list screen, monitor screen, and current position screen. The NEXT MENU Key toggles between the status screen, function screen, and keyboard screen. When you presses TEACHING Key, STATUS Key, and NEXT MENU Key for the pull-down menu method, the key of the selection of the menu such as TEACHING Screen, Displaying ‘Screens are displayed in the lower of a pertinent key. 318 May 17, 20011: ;OLLER HE Kawasaki Cee CORN HSE rANRUING MANUAL SWITCHES AND KEYS 3.2.3.3 SELECTION KEYS FOR AUXILIAM PROGRAM DATA \e The keys shown above are used to select the auxiliary program data used for block step teaching and editing. The function of each key is described in table 3-6. Table 3-6 Function of Selection Keys for Auxiliary Program Data Function The TEACH DATA key provides access to the keys of the auxiliary program data. INTERE| vownt | The INTERP (interpolator) key selects and displays the path interpolation the robot will use during playback of a program step. This key toggles between joint, linear, circular 1 (CIR1), and circular 2 (CIR2) interpolation. The SPEED key selects and displays the speed that the robot will use during playback of a program step. This key toggles between speeds 1 through 9. When the option for direct designation of speed is selected, speed will be displayed as follows. 89910.0mm/s The screen for direct designation of speed is accessed by pressing the SPEED key while holding down AUX SET & DISP key, when speed is shown 10ommis. goo May 17, 2001 3-191 C SERIES CONTROLLER: B-& Kawasaki Sor UTONS OPEC eee ca SWITCHES AND KEYS Table 3-6 Function of Auxiliary Program Data Selection Keys (Continued) { rcou} ae | The ACCU (accuracy) key selects and displays the accuracy level that the robot will use during playback of a program step. This key toggles be- tween accuracy 1 through 4. The TIMER key selects and displays the timer that will be used during playback of a program step. This key toggles between timer 0 through 9. ‘Timer 0 indicates that a timer has not been selected. The TOOL key selects and displays the too! that will be used during the playback of a program step. This key toggles between tool 1 through 9 The WORK key selects and displays the work coordinate that will be useq| during playback of a program step. This key toggles between work 0 through 9. The JE (umplend) Key is used in conjunction with the RPS (random program selection) function or jump function to determine at what step of a| program that a program changeover (call) should occur. This key toggles between jump, end, and blank. The COMMENT key selects a comment for a program step that will de- scribe the function of or work performed at the step. This key selects the clamp ON/OFF. Operable the MANUAL CONDUCTION. ON€SOFF The content of displaying is different depending on the specification of each clamping Spot welding specification: CL, WS, CC, and O/C has displayed. Handling specification: CL, CC has displayed. Painting and ceiling painting: CL, CC and GS has displayed. WS, CC, O/C, and GS are only displaying, and even if you presses this key, it is not possible to change in data, Itchange the “Auxiliary 14 CLAMP SPECIFICATION’ Screen if you presses this key while pressing AUX SET & DISP key. And, you can set clamp. 3-20 May 17, 2001C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL. B-—& Kawasak SWITCHES AND KEYS 3.2.3.4 CLAMP AND SIGNAL SELECTION KEYS The keys shown above are used to select the program data that will turn clamps ON and OFF, open and close retractable clamps, select weld schedules, clamp conditions, and allow output signals to be forced ON and OFF manually. The function of each key is described in table 3-7. Table 3-7 Function of Clamp and Signal Selection Keys Function ‘The CLAMP SIGNAL key toggles between the clamp selection keys and signal selection keys. The CLAMP ON/OFF keys select and display the clamps that will turn ON or OFF during the playback of a program step. ‘The WS (weld schedule) key selects and displays the weld schedule ws number that will be sent to the weld controller during the playback of a ° program step. May 17, 2001 3-21HE Kawasaki PERATIONS AND PROGRAMMING MANUAL SWITCHES AND KEYS Table 3-7 Function of Clamp and Signal Selection Keys (Continued) The CC (clamp condition) key selects and displays the clamp condition that the robot will use during the playback of a program step. This key toggles between clamp condition 0 through 9. ‘Clamp condition 0 indicates that a clamp condition has not been selected. | le] The O/C (open/close) key selects and displays the opening and clos- ing of a retractable gun during the playback of a program step. The SIG1~8 keys are used to force outputs ON or OFF. An ON state is| indicated by the LED in the upper left corner of the key. A key with a dark border indicates the signal is dedicated to a specific condition and cannot be forced ON or OFF. The up/down cursor keys select the next and previous screens. 3-22 May 17, 2001C SERIES CONTROLLER HE Kawasaki Cee DO HSCRANAANG MANUAL SWITCHES AND KEYS 3.2.3.5 OX (OUTPUT EXTERNAL) AND WX (WAIT EXTERNAL) SELECTION KEYS ‘The keys shown above are used to select output signals (OX) and input signals (WX) for program steps. The function of each key is described in table 3-8. Table 3-8 Function of OX and WX Selection Keys Key Function \ ox The OX/WX key toggles between the output signal and input signal \ wx selection keys. The OX keys select the output signals that will be sent during the play- back of a block step program step. These keys toggle ON and OFF. A key with a dark border indicates the signal is dedicated to a specific condition, and cannot be selected for program use. The number of available outputs is dependent upon total system I/O, but only signals 1~64 can be used in block step programming May 17, 2001 3-23m-& Kawasaki OPERATIONS AND PROGRAMMING MANUAL SWITCHES AND KEYS Table 3-8 Function of OX and WX Selection Keys (Continued) ‘The WX keys select the input signals that the robot will wait for during the playback of a program step. These keys toggle ON and OFF. A wa | | we | | key with a dark border indicates the signal is dedicated to a specific condition, and cannot be selected for program use. The number of available inputs is dependent upon total system I/O, but only signals 1~64 can be used in block step programming. The up/down cursor keys select the next and previous screens. The keys shown above are used to record and edit program steps. The function of each key is described in table 3-9 ‘Table 3-9 Function of Record and Teach New Keys Key Function The RECORD key is used to record program data in the teach mode and teach new mode. When this key is pressed, program data will either be recorded as a new block step or will modify an existing block step. 3-24 May 17, 20011 C SERIES CONTROLLER: mi -& Kawasaki cee ieee re SWITCHES AND KEYS Table 3-9 Function of Record and Teach New Keys (Continued) Key Function f When you specify the writing method to the step of the record operation, uses f=] this key. When you press this key, sub screen to select teaching mode is displayed as shown in figure below. It returns to former Screen when you presses this key gain. TEACHING(BLOCK TEACHING) It becomes displaying “NEW" for a new step. However, DELETE mode moves to replace OVERWRITE mode after every one step record. 3.2.3.7 AUX SET & DISP KEY AUX | iary data used for teaching block step programs. You can call set information on each Auxiliary data by pressing each key to “Auxiliary data” while pressing this key. You can changes/confirm the content of Auxiliary data. Itchange the “Auxiliary 114 CLAMP SPECIFICATION’ Screen if you presses CL1 and the CL2 key while pressing this key. And, you can set clamp. May 17, 2001 3-251 C SERIES CONTROLLER: H-& Kawasaki eDreams SWITCHES AND KEYS 3.2.3.8 SKEY | i The § key shown above is used in conjunction with the auxiliary data keys (TOOL, TIMER, ACCU, SPEED, WORK) and causes the auxiliary data key selections to appear in a descending order i.e., 9-8-7-6-5-4-3-2-1-0. 3.2.3.9 CHECK MODE KEYS The keys shown above are used to check a newly taught or edited program prior to play- back in repeat mode. The function of each key is described in table 3-10. Table 3-10 Function of Check Mode Keys Key Funetion Type Type 2! The CHECK ONCE key toggles between ONCE and CONT (CON- one TINUE), and selects the method for step selection in check mode once ONCE stops the robot at the point of axial coincidence of each taught point. CONT keeps the robot moving until the CHECK FORWARD or CHECK BACKWARD keys are released. 1 ie Hid 2 | When the CHECK BACKWARD key is pressed, the robot moves to o~ the previous step of the program. The robot stops moving when the a (-) key is released. Type? Type2 When the CHECK FORWARD key is pressed, the robot moves to the next step of the program. The robot stops moving when the key is released. CHECK Type 1 Type2 : Hf the robots speed of motion during check operations. ‘SPEED Fe Displays the next step. next | oe 3-26 May 17, 2001Bt - Kawasaki eee a SWITCHES AND KEYS Table 3-10 Function of Check Mode Keys(Continued) Key Function snus Swithes between Program Step display screens. Type 1 PROGRAM LIST (1/2), "PROGRAM LIST (2/2)”, "MONITOR (input sig- nal)’, MONITOR (output signal) Displays the program step in five lines around the step with the cursor. You sets “CHECK MODE" Screen in “ON” by “Auxiliary 96 ENVIRONMENT DATA OF PANEL”. And, when you presses the CHECK MODE key to the displayed pull-down menu when you presses TEACHING Key, Screen of the figure below is displayed. (option) Py a 7 ey | Ferrcowr rnc: figure below, and use a hard key. perc cueck| ‘once May 17, 2001 3-271 C SERIES CONTROLLER BE Kawasaki Roe aeNli aeeeeee SWITCHES AND KEYS 3.3.10 ROBOT MANUAL OPERATION KEYS The keys shown above are used to jog the robot in the teach mode. The function of each key is described in table 3-11. 3-28 May 17, 20011 'S CONTI B— Kawasaki Cee SONS HSC RAMMING MANUAL SWITCHES AND KEYS Table 3-11 Function of Robot Jogging Keys Key Function The MAN.SPEED key selects and displays the speeds for jogging and check mode operation. This key toggles between three available speeds. Selected speed is indicated by the number of highlighted vertical LED's i.e., one LED = speed 1, two LED's = speed 2, three LED's = speed 3. The LED in the upper left corner lights up any time the key is pressed to indicate this as the active mode. The INCHING key selects and displays the distance for inching and check mode operation. This key toggles between three avail- able distances. Selected distance is indicated by the number of highlighted vertical LED's i.e., one LED = distance 1, two LED's = distance 2, three LED's = distance 3. The LED in the upper left corner lights up any time the key is pressed to indicate this as the active mode. “OFF | oR) vo The EXT.AXIS/ROBOT key is used to select additional axes in the. robot system for jogging. The appearance of this key will vary depending upon system configuration. If the robot system is configured for 7 axes the key will toggle between EXT.AXIS OFF and EXT.AXES ON. If the robot system is configured for two arm control the key will toggle between ROBOT1, ROBOT2, and CO- OPERATION. This key will not appear on the 6-axes robot system ‘multi function panel. ‘The COORDINATE key selects and displays the coordinate system that will be used for manual robot operation. This key toggles between JOINT, BASE, and TOOL coordinate systems. The AXIS keys select robot axes and directions of movement. The labeling of each key will vary depending upon the coordinate tem selected for operation. if join lected, the keys will be labeled 1~6. If base or tool coordinates are selected, the keys will be labeled X, Y, Z, RX, RY, RZ. NOTE: This key is not displayed on Type2 Multi-Function Panels. Instead, use the actual Axis key. May 17, 2001 3-291 csi TROLLER: B- Kawasaki Sern NERDS inca SWITCHES AND KEYS 3.2.3.11 KEYBOARD The keyboard shown in figure 3-11 is used to enter AS language commands. The function of the keys is explained in table 3-12. “NEXT.PAGE” key “NEXT.MENU’ key "BS" key “CTLL* key Bs CTLaL ff nex eg SHIET “Space” key “SHIFT” key “ENTER’ key Figure 3-11 Keyboard Table 3-12 Function of Keyboard Keys ‘Switch Function The BS (back space) key is used to delete characters one at a time. The NEXT MENU key toggles between the status and keyboard screens. <)] | The ENTER key is used to set AS language commands. 3-30 May 17, 20011 C SERIES CONTROLLER B—& Kawasaki Perrone nO Poe STF AINA SWITCHES AND KEYS Table 3-12 Function of Keyboard Keys (Continued) The SHIFT key selects the upper character of dual character keys. (€.9., | Pushing shift+1 produce “!”.) The CTL+L key is used to display lines of previously input data. (up to 10 certat| lines old) SPACE Key | The SPACE key is used to input a blank space into a character string, May 17, 2001 3:31H-E Kawasaki OSERATIONS AND PROGRAMMING MANUAL SWITCHES AND KEYS ‘Type2 Multi-Function Panels display coordinates for manual operation, Manual speed, and Check motion mode as below: PERT TTS RHE welitttelelsts|slol=] > pb | olwietritiyiuli lo Pd falsfoleteln}yixle leet! gam ne = owl MODE:JOINT T.SPEED:1 (CHECK:ONCE BASE 2 CONTINUE TOOL 3 MODE : Manual movement coordinate JOINT : Joint BASE : Base TOOL : Tool T.SPEED : Manual speed 1-3 CHECK : Check motion mode ONCE : Check once CONTINUE : Check continue Display tine Input ine sisl>{slo]o]= alu . * Pert jon surf SD) [NOTE] The input and display lines may be divided according to the software version. 3-32 May 17, 20011 C SERIES CONTROLLER: HE Kawasaki SEER one eRSor ATG MANUAL SWITCHES AND KEYS ACCU key, 3-19 AUX SET & DISPLAY key, 3-25 Auxiliary data area, 3-16 AUXILIARY PROGRAM DATA SELECTION KEYS, 3-19 AXIS keys, 3-29 BACKWARD key, 3-27 BS key, 3-30 C5X Controller, 3-5 C70 Controller, 3-6 C80 Controller,3-7 CC key, 3-22 CHECK BACKWARD key, 3-15, 3-26 CHECK FORWARD key, 3-15, 3-26 Check mode, 3-27 CHECK MODE KEYS, 3-26 CHECK ONCE key, 3-26 Clamp key, 3-15, 3-20, 3-21 CLAMP AND SIGNAL SELECTION KEYS, 3-21 CLAMP ON/OFF key, 3-21 CLAMP SIGNAL key, 3-21 CNT key, 3-26 COMMENT key, 3-20 Contrast adjustment, 3-11, 3-13 CONTROL PANEL SWITCHES, 3-8 Control Power Indicator, 3-8 CONTROLLER, 3-2 COORDINATE key, 3-14, 3-29 CTL+L key, 3-31 Cursor key, 3-24 Cursor keys, 3-22 CYCLE START switch, 3-9 DISPLAY CHANGE key, 3-27 EMERGENCY STOP switch, 3-9, 3-11, 3-13 ENA key, 3-13 ENTER key, 3-30 Error Lamp, 3-8 Error Reset Switch, 3-8 EXTAXIS/ROBOT key, 3-29 FORWARD key, 3-27 Hour Meter, 3-8 INCHING key, 3-29 Intertace key,3-15 INTERP key, 3-19 May 17, 2001 3-33C SERIES CONTROLLER BE Kawasak Sree Hoe Vain NN SWITCHES AND KEYS JIE key, 3-20 keyboard, 3-30 LCD backlight, 3-11 Liquid crystal display, 3-11, 3-13, MAN.SPEED key, 3-29 MOTOR POWER switch, 3-9 MULTI FUNCTION PANEL(Type 1), 3-10 MULTI FUNCTION PANEL(Type 2), 3-12 MULTI FUNCTION PANEL DISPLAY AREAS, 3-16 MULTI FUNCTION PANEL TOUCH KEYS, 3-17 NEXT MENU, 3-18 NEXT MENU key, 3-30 NEXT STEP key, 3-26 North American C Controller, 3-3 O/C key, 3-22 OX and Wx Selection keys, 3-23 OX key, 3-23 OX/WKX key, 3-23 PC card slot, 3-11, 3-13 PC key, 3-17 Pull down menu, 3-18 PROGRAM AND STEP SELECTION KEYS, 3-17 PROGRAM key, 3-17 REC key, 3-15, 3-24 RECORD AND TEACH NEW KEYS, 3-24 RECORD key, 3-24 ROBOT manual operation KEYS, 3-28 Run/Hold Switch, 3-8 S key, 3-26 SCREEN SELECTION KEYS, 3-18 SHIFT key, 3-13, 3-31 SIG key, 3-22 SPACE key, 3-31 SPEED key, 3-14, 3-19, 3-26 Standard C Controller, 3-2 STATUS area, 3-16 STEP key, 3-17 gee ca nC ges occa aeeeaa aaa aaaeaaaeases sees secaeacasasasaces| jystem message area, 3-16 TEACH DATA key, 3-19 Teach lock, 3-11, 3-13 TEACH NEW key, 3-25, Teach/Repeat Switch, 3-8 TEACHING key, 3-18 3-34 May 17, 2001—& Kawasaki CES NO HOG ANANG MANUAL SWITCHES AND KEYS Teaching screen auxiliary information displaying area, 3-17 TIMER key, 3-20 Title area, 3-16 TOOL key, 3-20 Touch panel pen, 3-11 trigger switch, 3-11, 3-13 WORK key, 3-20 WS key, 3-21 WX key, 3-24 Figure 3-1_Standard C Controller Figure 3-2 North American ntroller Figure 3-3 European C Controller Figure 3 -4_C5X Controller Figure 7 ntroller Figure 3 6 C80 Controller Figure 3-7 Multi Function Panel(Type 1 Figure 3-8 Multi Function Panel(Type 2) Figure 3-9 Multi Function Panel Display Figure 3-10 Robot System Conditions Figure 3-11_ Keyboard Table 3-1 Control Panel Switches Table 3-2 Multi Function Panel(T) 1 ‘able 3-3 Multi Function Panel(Type 2) -4 Function of Program ani lection Keys Table 3-5 Function of Screen Selection Ki Table 3-6 Function of Auxiliary Program Di election Keys Table 3-7 Function of Clamp and Signal Selection Keys Te }-8 Function of Ox and WX Selection Ke Table 3-10 Function of Check Mode Keys Table 3-11 Function of Robot Jogging Keys Table 3-12 Function of Keyboard Keys May 17, 2001 3-35UNIT 1 OVERVIEW UNIT 2 SAFETY UNIT 3 SWITCHES AND KEYS. —___I___.. UNIT 5 BASIC MULTI FUNCTION PANEL OPERATIONS, ee UNIT 6 MANUAL OPERATION yaa aaa acatane cesoaiaauaisaaalaas UNIT 7 RECORDING AND EDITING PROGRAMS. a UNIT 8 PROGRAM EXECUTION a ae ceee ees UNIT 9 AUXILIARY FUNCTIONS, UNIT 10 ERROR CODES/HELP INFORMATION UNIT 11. OPTIONAL FUNCTONS UNIT 12. RESERVED APPENDIX ii (et GLOSSARY SE INDEXi ‘C SERIES CONTROLLER B-—& Kawasaki Cerrone OPrOos se A POWER ON/OFF PROCEDURES POWER ON/OFF PROCEDURE: Controller Power On/Off Procedures .. Controller Power On Procedures Controller Power Ot Procedures ... Servo Motor Power-On Procedures... Servo Motor Power-On In The Repeat Mode... Servo Motor Power-On In The Teach Mode Methods For Stopping The Robot. Emergency Stop Switch .. Hold/Run Switch .. Teach/Repeat Switch .. May 17, 2001 441 C SERIES CONTROLLER BE Kawasaki Soe ered re ert POWER ON/OFF PROCEDURES. 4.0 POWER ON/OFF PROCEDURES This unit provides the power ON/OFF procedures for the robot controller and servo motors. Refer to figures 4-1 through 4-12 during these procedures. 4.1 CONTROLLER POWER ON/OFF PROCEDURES. 4.1.1 CONTROLLER POWER ON PROCEDURES 1. Ensure that all personal are clear of the work cell, and that all safety devices are in place and operational 2. Turn the HOLD/RUN switch to the HOLD position. 3. Place the controller main disconnect switch in the ON position. At this time the CON- TROL POWER indicator lamp will illuminate. 4.1.2 CONTROLLER POWER OFF PROCEDURES: 1. Turn the HOLD/RUN switch to the HOLD position; the robot will decelerate to a stop. 2. Press the EMERGENCY STOP switch. At this time the CYCLE START and MOTOR POWER lamps will be turned off. 3. Place the controller main disconnect switch in the OFF position. 42 May 17, 20011: C SERIES CONTROLLER HE Kawasaki CES ONE CHC Sa NAVRNG MANUAL POWER ON/OFF PROCEDURES: Control Power Indicator ~ Main Disconnect 7 Switch Figure 4-1 Standard C Controller May 17, 2001 43C SERIES CONTROLLER OPERATIONS AND PROGRAMMING MANUAL HE Kawasaki POWER ON/OFF PROCEDURES Disconnect ‘Switch Com Power Indicator cy e@ Figure 4-2 North American C Controller 44 May 17, 20011 C SERIES CONTROLLER -& Kawasak See ee Se a URIRGNANUAL POWER ON/OFF PROCEDURES Disconnect —__ Switch g Control Power Indicator Cc] ©e al) Figure 4-3 European C Controller May 17, 2001 45i C SERIES CONTROLLER BE Kawasak GGFR ne PROGRAMMING MANUAL POWER ON/OFF PROCEDURES Control BR [ S be "a Power ‘Switch r ooo a Pop | Do Voy Figure 4-4 C5X Controller 46 May 17, 20011 IES CONTROLLER: BE Kawasaki pee eee POWER ON/OFF PROCEDURES Control Power Indicator ‘| Disconnect Switch Figure 4-5 C70 Controller May 17, 2001 47i C SERIES CONTROLLER HE Kawasaki Gaerne AND PROGRAMMING MANUAL POWER ON/OFF PROCEDURES Disconnect — © Switch 2 Te. “Waeeb bce Figure 4-6 C80 Controller 48 May 17, 20011 C SERIES CONTROLLE! BE Kawasaki Coe OEE sauna MANUAL POWER ON/OFF PROCEDURES Figure 4-7 North American and Figure 4-8 C5X Controller Switch Panel European C Controller Switch Panel cous. ROR ERRORRESET. HOLD FIN. TECH REPEAT CIGESTANT_ UOTORPOWEREMEREENE SOP Fane a) feceees es Figure 4-9 Standard C Controller Switch Panel May 17, 2001 491 ;OLLER H-~E Kawasaki OPERATIONS AND PROGRAMMING MANUAL POWER ON/OFF PROCEDURES: eras | | Figure 4-10 C70 Controller Switch Panel Figure 4-11 C80 Controller Switch Panel 410 May 17, 20011 C SERIES CONTROLLER —-& Kawasak Ca ees Mumm MANUAL POWER ON/OFF PROCEDURES 4.2 SERVO MOTOR POWER-ON PROCEDURES 4..2.1. SERVO MOTOR POWER-ON IN THE REPEAT MODE 1. Place the TEACH/REPEAT switch in the REPEAT position. 2. Place the HOLD/RUN switch in the HOLD position. 3. Press the MOTOR POWER push button. The MOTOR POWER lamp will illuminate. 4, Place the HOLD/RUN switch in the RUN position. The robot is now ready to execute a program. 4.2.2, SERVO MOTOR POWER-ON IN THE TEACH MODE 1. Place the TEACH/REPEAT switch in the TEACH position. 2. Place the TEACH LOCK in the ON position. 3. _ Press one of the deadman switches and press the MOTOR POWER push button. At this time the MOTOR POWER lamp will illuminate. Emorgorey Sap Teach Lock 629 emergency sot Tesoro pte = ‘ Stop ‘Switch ~~ Scher —~Deadman ‘Switches (Rear side) Figure 4-12 Multi Function Panel(Type 1) Figure 4-13 Multi Function Panel(Type 2) May 17, 2001 anKawasaki Rise tiered ene POWER ON/OFF PROCEDURES 4.3 METHODS FOR STOPPING THE ROBOT One of three methods can be used to stop robot motion. Each of these methods is de- scribed in the following sections and shown in figure 4-14. 4.3.1. EMERGENCY STOP SWITCH When the EMERGENCY STOP switch is pressed, motor power will be turned off and the brakes will be applied stopping the robot immediately. This places very high loads upon the robot and is only recommended for emergency situations. To stop the robot during non- emergency situations refer to section 4.3.2. 4.3.2. HOLD/RUN SWITCH When the HOLD/RUN switch is turned to the HOLD position the robot will decelerate smoothly to a stop and the brakes will be applied. This places the robot into a temporary stop condition (the CYCLE START and MOTOR POWER indicator lamps remain on). When the HOLD/RUN switch is again turned to the RUN position the robot will continue the motion it had been executing prior to HOLD. To create a permanent stop condition, press the EMERGENCY STOP switch or turn the TEACH/REPEAT switch into the TEACH posi- tion (the CYCLE START and MOTOR POWER indicator lamps will turn off in either case). 4.3.3. TEACH/REPEAT SWITCH When the TEACH/REPEAT switch is turned to the TEACH position motor power will be turned off and the brakes will be applied stopping the robot immediately. This places very high loads upon the robot and is only recommended for emergency situations. To stop the robot during non-emergency situations refer to section 4.3.2. 4-12 May 17, 20011 C SERIES CONTROLLER: mi -& Kawasaki Geren reese POWER ON/OFF PROCEDURES Switches used for the stoppage of Robot Ee | EMERGENCY STOP Syn TEACH _ REPEAT Emergency Stop PUSH Figure 4-14 Methods of Robot Stoppage May 17, 2001 4137 IES CONTROLLER B—& Kawasaki ee eee POWER ON/OFF PROCEDURES Emergency stop switch, 4-12 Hold/run switch, 4-12 Methods for stopping the robot, 4-12 Power on/off procedures, 4-2 Servo motor power-on procedures, 4-11 Teach/repeat switch, 4-12 Fi - indar« ir Figure 4-2 North American C Controller igure 4-3 European ntroller Fi + X Controller Figure 4-5 C70 Controller igure 4- ler Figure 4-7 North American and European C Controller Switch Panel Figure 4-8 C5XController Switch Panel Figure 4-' ir ntroller Switch Panel Figure 4-1 7 roller Switch P: Figure 4-11_C80 Controller Switch Panel Figure 4-12 Multi Function Panel(Type 1 Figure 4-13 Multi Function Panel(T) ‘igure 4-14 Meth 414 May 17, 2001UNIT 1 OVERVIEW UNIT 2 SAFETY UNIT 3 SWITCHES AND KEYS UNIT 4. POWER ON/OFF PROCEDURES UNIT 6 MANUAL OPERATION PReciecece ee eee ieeeee cece ceeeeces UNIT 7 RECORDING AND EDITING PROGRAMS UNIT 8 PROGRAM EXECUTION UNIT 9 AUXILIARY FUNCTIONS. ————_|_— UNIT 10 ERROR CODES/HELP INFORMATION UNIT 11. OPTIONAL FUNCTONS ——— UNIT 12 RESERVED es es APPENDIX eee eee eee cea seam eaaaaaauauaualeaaalaceuauaeaucecies GLOSSARY a INDEXm-& Kawasaki Cee ae BASIC MULTI FUNCTION PANEL OPERATIONS BASIC MULTI FUNCTION PANEL OPERATIONS Screen Selection Keys Teaching Key Next Menu Key. Status Key Status Screen - Program List Screens... Monitor Screen . Current Position Screen Cursor Movement Keys. Figure Input And Cursor Selection . Character Input : Program Selection .. Step Selection... May 17, 2001 54i 'S CONTR HE Kawasaki Cee TN oe a saaiRG MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS 5.0 BASIC MULTI FUNCTION PANEL OPERATIONS This unit provides information on the use of the screen selection, program selection, and step selection keys, an explanation of the data contained on the various STATUS screens, and the use of the cursor, menu selection, and character input keys. 5.1 SCREEN SELECTION KEYS The three keys used for screen selection are shown in figure 5-1. Two of the keys, labeled TEACHING and NEXT MENU, are dedicated. The third key, located between TEACHING and NEXT MENU, is dynamic and will toggle between STATUS and FUNCTION when the NEXT MENU key is pressed. a > rexcrna) srarus [wexrwen, Figure 5-1 Screen Selection Keys 5-2 May 17, 2001i C SERIES CONTROLLER: HE Kawasaki SeeaTONe ND rCl nines ain BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.1 TEACHING KEY Se 7 ad ; >| m7 ng =| >| work JE ' +P] Twat gate Ar Figure 5-2 Teaching Menu Screen eas) > TEACHING(BLOCK TEACHING) Screen [=| => AS INSTRUCTION TEACHING Screen tocmen| > AS INSTRUCTION TEACHING(LOCATION DATA) Screen ‘or| > PROGRAM EDIT Screen = CHECK MODE Screen May 17, 2001 531 cst ;OLLER B-~E Kawasaki Serneue rece sr BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.2 NEXT MENU KEY lr Figure 5-3 Next Menu Screen STATUS Screen > AUXILIARY FUNCTION Screen > INTERFACE PANEL Screen => KEYBOARD Screen 5-4 May 17, 20011 IES CONTROLLER: BE Kawasaki Cee TOLLE uaa MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.3 STATUS KEY cr a ‘2000 “0.000 “0.000 “0.000.000 “0.000 2 20000 e300 _0.003_ 0.007 _.008 Figure 5-4 Status Menu Screen > __ STATUS Screen => PROGRAMLIST Screen => MONITOR Screen SS May 17, 2001 557 c ;OLLER: HE Kawasaki Seeks roe ih usa BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.3.1. STATUS SCREEN The STATUS screen, shown in figure 5-5, provides basic system information such as the current program, step/repeat conditions, time and date, switch status, and robot position. Refer to table 5-1 for more information about the STATUS screen. ) Type 2 Multi-Function Pan- + 3. els display the light coner of 1) the Status screen (in Teach Model) is flows: Tee PO = 5 (eesti Eas [TEACHING] STATUS ext wo RELEASE if Hage} 5 eourccoe ‘SUMOVE tet {TIOINT SPEEDS ACCUI TMERO TOOL WORKO CLAMP 1 (OFF 15,1.C)_ Ye dh dle fh oie a sozisg0 6864487 1028774 -shues 115800 46.616 Figure 5-5 Status Screen Table 5-1 Status Screen Explanation No. item Description ‘The REPEAT key selects and displays the current monitor REPEAT | speed, Adjustments of the speed are made in increments of 10%. : repeat __ |The REPEAT CONDITION key selects the step (STEP CONT/ ONCE), program, (REPEAT CONT/ONCE), and mode ‘GONDITION SE poe ir dom P ect) ‘The STEP FORWARD key appears when STEP ONCE has STEP FORWARD | been selected with the REPEAT CONDITION key, and is used to execute the next step of a program. 56 May 17, 2001i C SERIES CONTROLLER BE Kawasaki See ain BASIC MULTI FUNCTION PANEL OPERATIONS Table 5-1 Status Screen Explanation (Continued) No. tem Description 2 | Program Display Area Displays the steps of the program currently selected, high lighting the step is progress. 3. | Repeat Conditions Monitor Speed Date/Time Displays the settings of the repeat conditions and moni- tor speed as well as the date and time. 4 ‘Switch Status Displays the current setting of the switches located on the interface panel. Push button switches will change color to indicate an ON/OFF change, rotary switches will turn to indicate the switch position. 5 | RECORD ACCEPT Displays the settings of the AUX 71 function, which pro- hibits or allows the teaching of programs. 6 | Position Display Displays the current position of the robot as joint angles and Cartesian coordinates. May 17, 2001 571 C SERIES CONTROLLER: H-& Kawasaki Soncnsite see ica BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.3.2. PROGRAM LIST SCREENS The PROGRAM LIST screens, shown in figure 5-6, display the instructions within each step of the current program. Screen 1 of 2 (1/2) displays AS language instructions and block step auxiliary data (interpolator, speed, accuracy, timer, tool, work, jump/end, and OX and WX signal numbers). Screen 2 of 2 (2/2) displays the clamp data for block step programs. Press the NEXT PG and PREV. PG keys to select screens. The step that is being ex- ecuted will be displayed in reverse video. + When five more clamp are used, the data is displayed in PROGRAM LIST (3/3). + Itmakes the program step forward/backward every five lines centering on the step when you press the FORWARDt / BACKWARDs key in the step with the cursor and displays program step. hot 1 _Aamemmuetsasn _E SL ° ia ° toss 0 NOW AO) AOFRO..0) HOKR0.0) How.aec) NOFEIS.6) _AOFF.01.0) _30F.0.0.0)_HOFR 2.8.6) OTe ASD oO an aor se NOFRIGAG) -AOFRO1.0) 90.0.0.0) 4OFF9.8.c) Norm iene) ROFFAN.o} S000.) 410N.88.0) NOWIRNO) —-AOFRA.0) 3!FR0.0.0) 4OFFO.8,c | Figure 5-6 Program List Screen 58 May 17, 2001B-E Kawasaki Serene Oees cant BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.3.3 MONITOR SCREEN ‘The MONITOR screens, shown in figure 5-7, display the input, output, and status of internal signals (on or off). Press the INPUT, OUTPUT, or INTERNAL keys at the bottom of the screen to select the type of signal to monitor. Press the NEXT PG and PREV.PG keys to view the next or previous page of signals. Signals in an ON state are high lighted. Press the GRAPH key to view the selected signals (1~64 only) on a time based graph as shown in figure 5-8. ASAT 5 STATES Figure 5-7 Monitor Screen * The INTEGER DATA key is displayd when the “Interal sequencer function” option is ON. INPUT signal :IN*** OUTPUT signal :OUT"** The INPUT OUTPUT key may also be displayed (as shown below). May 17, 2001 59i C SERIES CONTROLLER BE Kawasaki SSeS CONNORS GRAMMING MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS Pressing the INPUT OUTPUT key results of the following screen: i 5-10 May 17, 20011: C SERIES CONTROLLER HE Kawasaki Cee SOND HOG RAMMING MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS The graph will display up to 16 signals at a time. To view the next 16 signals, press the GRAPH key a second time. To stop and restart the graph update, press GRAPH STOP/ GRAPH START. Pressing GRAPH EXIT will return to the previous monitor display. [onronorar soma 2 one TeaKie Ye WINS? 26 0128 yeoxie 1 WCIWSE 28 TEACH MOOE Figure 5-8 Monitor Mode I/O Graph ‘The customer can set name of signal displayed in MONITOR Screen. May 17, 2001 5-111 ;OLLER: HE Kawasaki See OH oe AMRMNGHANUAL BASIC MULTI FUNCTION PANEL OPERATIONS The customer can set name of signal displayed in MONITOR Screen. We shows the setting method as follows. 1. Saves Auxiliary data, SAVE/JA name or, Select “3 Auxiliary data” in “Auxiliary 10 MEMORY >PC_ CARD’, and save. 2. Add the following signal by using the editor of the personal computer between AUXDATA and .END filing of the saving. The output signal N_OX1 "Signal namet ” N_OX2 "Signal name2” The input signal N_WXt “Signal name1” N_WX1 “Signal name2” An internal signal N_INT1 “Signal name1” N_INT2 “Signal name2" Set an arbitrary name in Signal name. The number of characters : Within 14 bytes. ‘The number of signals which can be set is each output signal, input signal up to 1-64. 3. Load the file made in the editor. 4, Make, and load the item only of *” between .AUXDATA and .END when you delete the set signal name. N_OX1*" N_Wxt*" N_INT? Moreover, the name of Hardware Dedicated Signatis giverrto priority wherr the signat——— set as Hardware Dedicated Signal comes in succession. [NOTE] - Itreturns to the name at the beginning in case of system initialization (SYSINIT). 512 May 17, 2001BE Kawasaki CE AF Re IND PROGRAMMING MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS 5.1.3.4 CURRENT POSITION SCREEN The CURRENT POSITION screen, shown in figure 5-9, displays the current position of the robot in terms of joint angles and Cartesian coordinates. Joint angles represent the de- grees of rotation for each joint from the zeroed position. Cartesian coordinates represent the location and orientation of the tool center point relative to the base coordinate system. J a 26248 5513 97.812 71.102 75092 11.449 x Ve 592.690 656.487 1022.774-154.463 113.890 46.616 Figure 5-9 Current Position Screen 5.2 CURSOR MOVEMENT KEYS The cursor movement keys are used to select items or data entry fields. Figure 5-10 illustrates the use of the cursor keys for program selection | procmmnsenEer = | prognansetecr = vo rar fone Som Bae 7 o oka Loh 4 t Be elias Figure 5-10 Cursor Movement Keys May 17, 2001 5-13,Hs Kawasaki C SERIES CONTROLLER, OPERATIONS AND PROGRAMMING MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS 5.3 FIGURE INPUT AND CURSOR SELECTION Various screens allow selections to be made by figure input or cursor key. Program selec- tion, editing, and the AUX menu allow selections to be made either way. Figure 5-11 illustrates AUX menu selection using both methods. a Searcy ence seamen FPP rex pal ext ro OX 1» Locations seer Diseta¥ Locaniowa spec oisruae HS oaratranseen Daa THaNsren Skt pnoceaw Rut progRaM fo Menor” Pe can is Peano MEWORY 3, Baeanvension is PECARD, Mewony is micomectonrranecromn 1 mae omecTont necro ft Sebate se rerio }isrscare tox nero foxeron sownen Funeronwer, FS ESTE [a a] evra freshen Figure 5-11 Figure Input or Cursor Key Selection 514 May 17, 2001H-E Kawasaki Cee ROS SeaMMIRG MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS 5.4 CHARACTER INPUT Various screens allow character input through the keyboard. Screens that use AS lan- guage commands or the CHARACTER key, utiize the keyboard. Use the touch panel pen at the bottom of the multifunction panel to easily type characters from the keyboard. Press ‘the BS (back space) key to delete characters that have been typed. After the command, etc., is typed press the ENTER key. Press the NEXT MENU key to exit the character input mode. Figure 5-12 illustrates the use of the keyboard. 1 —- > cru Bextra} wer Figure 5-12 Character Input May 17, 2001 5-151 c }OLLER HE Kawasaki Genes un noes ec BASIC MULTI FUNCTION PANEL OPERATIONS 5.5 PROGRAM SELECTION The PROGRAM key is used to select programs for playback and editing, delete programs, create names for new programs (teach mode only), and display the selected program name. Three methods can be used to select programs; number keys, character keys, and cursor keys. When selecting programs with the number keys, be sure to highlight pg?? at the top of the program select screen. Figure 5-13 illustrates the use of the PROGRAM key for program selection. Figure 5-14 illustrates the program delete function. eyoi Tig OGRAMSELEC ire er icajo BHD 90 i oe a 4 | 8 | ccc exit eg owe 0 Figure 5-13 Program Selection Methods 5-16 May 17, 2001m-& Kawasaki Sh eee BASIC MULTI FUNCTION PANEL OPERATIONS To delete a program, select the program with the cursor keys then press the DELETE key. When asked for confirmation to delete, press ENTER to continue or EXIT to abort the process. The example in figure 5-14 shows program pg10 being deleted. [ofa =I u a ao Ok a dln program? (ENTERIEXT 4 4 Figure 5-14 Program Delete Function May 17, 2001 5171 SERIES CONTROLLE B-~E Kawasaki Cee OLE gina MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS 5.6 STEP SELECTION The STEP key is used to select steps for program playback and editing. Four methods of step selection are available using the FIRST STEP, BACKWARD, FORWARD, and STEP SELECT keys. The FIRST STEP key always selects step one of the program. BACK- WARD and FORWARD keys are used to navigate. The STEP SELECTkeyallowstodesignateaspecific step back forward. Whenastepnumbergreaterthenthe total number of steps is entered, the last step will be selected in the REPEAT mode and one step beyond the last will be selected in the TEACH mode (provided the teach lock is ON). Press the EXIT key to return to the previous mode. Figure 5-15 illustrates the use of the STEP SELECT key. Figure 5-15 Step Selection lemsrp A || W | ster! I'steP i SLES) ext ‘There are different ways to toggle between the first and final steps. * Press ‘FIRST STEP” key to select the head of the program when the key displaying is “FIRST STEP”. In the status to press S key, when displaying the "FIRST STEP” key becomes “FINAL STEP”. (When S key is displayed only at “TEACHING(BLOCK)TEACHING? Screen and “AS INSTRUC- TION TEACHING’ Screen.) * Press the BACKWARD key while pressing the FIRST FINAL key if you select the head of the program when the key displaying is FIRST FINAL. Press the FORWARD key while pressing the FIRST FINAL key ‘when you Select the final step of the pragram.Inthis case, the method of Step Selection does not change even if you press S key. * Press the STEP SELECT key when you designate the step (inputs the numeric). 518 May 17, 20011 cst '§ CONTROLLER HE Kawasaki Coen ee aMMING MANUAL BASIC MULTI FUNCTION PANEL OPERATIONS U Entering the Step number Making a Selection with the cursor key For example, to skip to number step 3. Select the desired step, navigating via the BACKWARD and FORAWARD- keys. Each press moves one step in the selected direction. — [NOTE] When the number entered is larger than the number of the final step, the next-to-last step is selected. Pressing the FINAL STEP key will displays the following: ‘(When TEACH mode and TEACH LOCK are ON) “FINAL4+1" step (When REPEAT mode and TEACH LOCK are OFF) “FINAL” step May 17, 2001 54191. IES CONTROL BE Kawasaki CEE EL man AML BASIC MULTI FUNCTION PANEL OPERATIONS Basic multi function panel operations, 5-2 Character input, 5-15 Current position screen, 5-13 Cursor movement keys, 5-12 Figure input and cursor selection, 5-11 Graph screens, 5-11 Monitor screens, 5-9 Next menukey, 5-4 Position display, 5-7 Program delete function, 5-17 Program display area, 5-7 Program list screen, 5-8 Program selection, 5-15 Pull down menu, 5-2 Record accept, 5-7 Repeat conation key, 5-6 Repeat key, 5-6 Screen selection keys, 5-2 Status key, 5-5 Status screen, 5-6 Step forward key, 5-6 Step selection, 5-18 Switch status, 5-7 Teaching key, 5-3 Figure 5-1 Screen Selection Keys Figure 5-2 Teaching Menu Screen Figure 5-3 Next Menu Menu Screen Figure 5-4 Status Menu Screen Figure 5-5 Status Screen Figure 5-6 Program List Screen Figure 5-7 Monitor Screen Figure 5-8 Monitor Mode /O Graph Figure 5-9 Current Position Screen Figure 5-10 Cursor Movement Keys Figure 5-11 Figure Input or Cursor Key Selection Figure 5-12 Character Input Figure 5-13- Program Selection Methods Figure 5-14 Program Delete Fun Figure 5-15 Step Selection Table 5-1 Status Screen Explanation 5-20 May 17, 2001UNIT 1 OVERVIEW a UNIT 2 SAFETY UNIT 3 SWITCHES AND KEYS. Psa ceeeeceeee ceceeceeeees UNIT 4 POWER ON/OFF PROCEDURES UNIT 5 BASIC MULTI FUNCTION PANEL OPERATIONS = UNIT 7 RECORDING AND EDITING PROGRAMS UNIT 8 PROGRAM EXECUTION ——— UNIT 9 AUXILIARY FUNCTIONS UNIT 10 ERROR CODES/HELP INFORMATION UNIT 11. OPTIONAL FUNCTONS | UNIT 12 RESERVED APPENDIX GLOSSARY INDEX1: SERIES CONTROLLER BE Kawasaki iS earone nb oes AIRC MANUAL OPERATION 6.0 MANUAL OPERATION . 6.1 Keys Used For Manual Operatior 6.2 Manual Operation Procedures .. 63 Operation of Optional Axes. 6.4 Coordinate Systems 6.4.1. Joint Coordinates 6.4.2 Base Coordinates 6.4.3 Tool Coordinates ... May 17, 2001 611 :S CONTROLLE BE Kawasaki SSE ERS ne oC RANMING MANUAL MANUAL OPERATION 6.0 MANUAL OPERATION This unit provides information for manual robot operation or jogging. Information provided includes the keys required for manual robot operation, movement modes, and an explana- tion of the coordinate systems. 6.1 KEYS USED FOR MANUAL OPERATION The keys used for manual robot operation, shown in figure 6-1 and 6-2, include the TEACHING key for teach mode selection, axis keys for direction or joint selection, COOR- DINATE key for coordinate system selection, MAN.SPEED key for speed selection, INCH- ING key for distance selection, EXT.AXIS or ROBOT key for optional axes selection, and trigger switches to enable motor power in the TEACH mode. COORDINATE Key ExrAsinoBor key INCHING Key MAN. SPEED Kay TEACHING Koy Figure 6-1 Manual Operation Keys (Type 1) 62 May 17, 2001B—& Kawasaki SEEENTORS MIE PROER AMAA MANUAL MANUAL OPERATION MAN.SPEED key COORDINATE Keykey | COORDINATE Key }—MAN.SPEED key TRIGGER Switch Figure 6-2 Manual Operation Keys (Type 2) May 17, 2001 63