FD CONTROLLER
INSTRUCTION MANUAL
CONTROL AND MAINTENANCE FUNCTION
・
Before attempting to operate the robot, please read through this operating manual
carefully, and comply with all the safety-related items and instructions in the text
.
・
The installation, operation and maintenance of this robot should be undertaken only
by those individuals who have attended one of our robot course
.
・When using this robot, observe the low related with industrial robot and with
safety issues in each country.
・
This operating manual must be given without fail to the individual who will be actually
operating the robot
.
・
Please direct any queries about parts of this operating manual which may not be
completely clear or any inquiries concerning the after-sale service of this robot to any
of the service centers listed on the back cover.
7th edition
Table of Contents
Table of Contents
Chapter 1 User Management
1.1 User management ... 1-1
1.1.1 Enabling user management ... 1-2
1.1.2 Automatic log-out setting ... 1-3
1.1.3 Registering the users allowed to perform the editing operations ... 1-3
1.1.4 Setting the user operation limitations ... 1-5
1.1.5 Copying user registration information ... 1-6
1.1.6 User information editing ... 1-8
1.2 Using the user management function... 1-9
1.2.1 Log-in operation... 1-9
1.2.2 Log-out operation ... 1-10
1.2.3 User information at log-in ... 1-11
Chapter 2 Edit logging
2.1 Concerning edit logging... 2-1
2.2 Referencing the edit logging... 2-2
2.2.1 Editor logging monitor displays ... 2-2
2.2.2 Editor logging monitor functions ... 2-7
Chapter 3 User Check
3.1 User Check ... 3-1
3.2 Setting the user check ... 3-2
3.2.1 Setting up the check item ... 3-2
3.2.2 Allocating input/output signals ... 3-6
3.2.3 When reaching the inspection timing ... 3-6
3.2.4 When check and part replacement are completed... 3-7
Chapter 4 Troubleshooting
4.1 When failure has occurred... 4-1
4.2 Concerning the failure details ... 4-2
4.2.1 Failure category... 4-2
4.2.2 Concerning criticality codes and failure codes ... 4-3
4.3 Concerning “System Failure”... 4-4
4.3.1 Outline of “System Failure”... 4-4
4.3.2 How to recover and response to the failures... 4-4
4.4 Recovery after failing of power down detection... 4-5
4.4.1 Recovery after failing of power down detection ... 4-5
4.4.2 Setting of start operation permission... 4-5
4.6.1 Function of the failure log monitor ... 4-15
4.6.2 Settings regarding the failure log... 4-16
4.6.3 Failure filtering function ... 4-20
4.6.4 Displaying the system failure log... 4-23
4.6.5 Frequency of the failure occurrence... 4-24
4.7 Failure list ... 4-27
Chapter 5 Robot Diagnosis
5.1 Robot Diagnosis ... 5-1
5.1.1 Program Diagnosis ... 5-1
5.1.2 OverHaul Time... 5-3
Chapter 1 User Management
This chapter describes the user management function.
1.1 User management ...1-1
1.1.1 Enabling user management ...1-2
1.1.2 Automatic log-out setting ...1-3
1.1.3 Registering the users allowed to perform the editing operations...1-3
1.1.4 Setting the user operation limitations ...1-5
1.1.5 Copying user registration information...1-6
1.1.6 User information editing ...1-8
1.2 Using the user management function ...1-9
1.2.1 Log-in operation ...1-9
1.2.2 Log-out operation ...1-10
1.2.3 User information at log-in ... 1-11
1.1 User management
1.1 User management
The user management function is a maintenance function designed to enable the robot to be operated safely in
an operating environment in which a multiple number of users will be operating one robot controller.
The function places limits on the editing operations performed by users for the robot, and allows only registered
users to perform the allowed editing operations. Even with the registered users, it limits the operations they can
perform by their level of experience: For instance, beginners may perform only simple setting operations whereas
experienced operators may perform sophisticated setting operations. In this way, the function prevents mistakes
that would be made if all editing operations were allowed for all users, and it does this by establishing a number of
user levels.
When the function is enabled, registered users must log in if they wish to perform editing operations. When users
log in, they can perform only those editing operations within the range allowed for their particular user level. If no
users have logged in, the protection level will be set to the BEGINNER status so no editing operations can be
performed.
Furthermore, when this function is enabled, the following operations for the protection level change (R314)
function are restricted.
(1) The protection level cannot be changed while a user has logged in.
(2) The protection level cannot be changed even when there is no logged-in user. However, in order to
manage this function, the level can be changed by an operator having the qualification as
SPECIALIST.
(3) When this controller starts up, it will always start up in the
BEGINNER status regardless of the <Constant
Setting> - [1 Control Constants] - [8 Protecting level select ion] setting.
IMPORTANT
•
“Editing operations” to be restricted by this function refers to operations to change
the constants of the robot system and to edit the task programs or condition files.
There are no restrictions on other operations without editing, such as check
operation, playback operation and monitor startup.
•
The qualification of operator can be switched to
SPECIALIST, even when this
function is enabled. It is therefore recommended to change the default
SPECIALIST password.
For details on the steps taken to change the password, see
Section 4.7.3
“How to change the passwords” in the “SETUP MANUAL”.
•
When the user management function is set to “enabled,” the following operations are
restricted for
BEGINNER operators.
•
Task program copying operations
•
Copying operations using
＜Service＞- [7 File Manager]
•
Step speed change operations
•
Step accuracy change operations
1.1.1 Enabling user management
The factory default setting of the user management function has been “Disabled.” But can be
turned to “Enabled” by the following operating.
The qualifications level of
SPECIALIST is required to carry out the functions described in this
section.
Enabling the user management function
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[1 User Management function].
≫ The screen on which to set user management is displayed.
＋
2
Bring the cursor to “User management function,” and press [ENABLE] +[right] to
select the “Enabled” setting.
3
After the setting has been established, press f12 <Complete>.
1.1 User management
1.1.2 Automatic log-out setting
The log-out operation will be automatically performed, after a certain period of time has elapsed
without any operation. Even if user forgot to log out, this function serves to secure the user
management function by preventing another user from operating the robot without permission.
POINT
The automatic log-out function is executed only in the teach mode. Log-out is not
implemented automatically in the playback mode.
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[1 User Management Function].
≫ When the user management function is set to “enabled,” the setting items for the
automatic log-out function are displayed as shown below.
＋
2
Bring the cursor to “Automatic log out function,” and press [ENABLE] +[right] to
select the “Enabled” setting.
3
Bring the cursor to “Automatic log out time,” and set the non-operation time.
4
After the setting has been established, press f12 <Complete>.
≫ The previous screen is restored.
1.1.3 Registering the users allowed to perform the editing operations
The first step which must be taken is to register the users who are allowed to perform the robot
editing operations. Users can be registered by following the steps described below. Up to 999
users can be registered.
To set the function, the operator must have the qualifications level of
SPECIALIST.
Registering the users
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[2 User Registration].
Table 1.1.1 User registration setting items
Data registered
Input range
Description
User ID (*)
3-digit number
from 001 to 999
This is the ID for identifying the users. With user management,
users are controlled using these IDs.
The same ID cannot be set for more than one user.
Password A
number
consisting of 0
to 8 digits
This is the numerical value data for authenticating users when
they log in.
If no data is input, there will be no password for users to enter.
User name (*)
1 to 14
characters
Input the name of the user to be registered here.
Protect level (*)
BEGINNER
USER
EXPERT
SPECIALIST
Enter the protection level of the user to be registered here.
Comment Max.
20
characters
Comments on users may be entered in this field.
Limited operation
Check box
ON/OFF
□Change program
□Change arc condition setting
□Change arc constant setting
□Change sensor condition setting
□Change sensor constant setting
□Conversion program
□File manager
Input is required for all the items indicated by an asterisk (*).
For details on the operation limitations, refer to
“Operation Limitations” in chapter 2.
2
Press f8 <Next User>.
≫The lowest ID among the currently unregistered user IDs is displayed in the “User
ID” field.
Press f9 <User List>.
≫A list of the currently registered users is displayed.
This key is used to switch the user listing method between ascending
order and descending order.
3
This key is used to delete the information of the selected user.
4
After the setting has been established, press f12 <Complete>.
≫The user information is registered, and the previous screen is restored.
1.1 User management
1.1.4 Setting the user operation limitations
This function serves to place limitations on some operations carried out by the registered users,
as shown in Table 1.1.1.
Table 1.1.1 Setting items of operation limitation function and descriptions of limitations imposed
Setting item
Description of limitation imposed
Change program
Limitations are imposed on the file operations (creating new files and copying,
deleting and renaming existing files) for task programs and on the editing
operations (step recording, insertion, deletion and overwriting).
Change arc condition
setting
Limitations are imposed on the selection operations for the <Service> -
[21 Arc Welding Application] menu.
Change arc constant
setting
Limitations are imposed on the selection operations for the <Constant Setting>
- [14 Arc Welding Application] menu.
Change sensor
condition setting
Limitations are imposed on the selection operations for the <Service> -
[29 Sensor Application] menu.
Change sensor
condition setting
Limitations are imposed on the selection operations for the <Constant Setting>
- [19 Sensor Application] menu.
Program conversion
Limitations are imposed on the selection operations for the <Service> -
[9 Program Conversion] menu.
File manager
Limitations are imposed on the selection operations for the <Service> -
[7 File Manager] menu.
Shown below is an example of a menu which appears when limitations have been imposed
on operation.
The menus which cannot be selected are shown in gray.
Fig. 1.1.1 Example of menu display when operations have been limited
Setting the operation limitations
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[2 User Registration].
≫ The screen on which to register the users is displayed.
＋
3
To set an operation limitation, press [1] while holding down [ENABLE].
≫A check mark (limitation) is now set in the box for the item specified.
＋
4
To release an operation limitation, press [2] while holding down [ENABLE].
≫The check mark (limitation) set in the box for the item specified is now removed.
5
After performing the settings, press f12 <Complete>.
≫ The settings are recorded.
1.1.5 Copying user registration information
The user registration information is stored in the “USERID.CON” filename. By copying this file
between robots, it is possible to transfer the user information from one robot to another. When the
same user information is used for managing two or more robots, it is more convenient to copy the
user registration information by the operations described below.
To perform this operation, the operator must have the qualifications level of
SPECIALIST or
above.
Writing the user registration information
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[2 User Registration].
≫ User registration screen appears.
2
Press f10 <File Write> on the user registration screen in section 1.2.3.
≫The folder and file in which the information is to be written are displayed.
3
Specify the folder in which the information is to be written, and press f12
<Execute>.
1.1 User management
Reading the user registration information
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[2 User Registration].
≫ User registration screen appears.
2
Press f11 <File Read> on the user registration screen in section 1.2.3.
≫The folder and file from which the information is to be read are displayed.
3
Specify the file from which the information is to be read, and press f12
<Execute>.
≫ If there are no problems in the file which is read, the file is read, the user
information is then updated, and the previous screen is restored.
≫ If you try to read in the same user ID as the registered one, a message confirming
whether or not to overwrite the existing data appears as shown below. Select “Yes”
only for the ID to be updated.
1.1.6 User information editing
Registered user information can be edited by taking the steps below.
To perform this operation, the operator must have the qualifications level of
SPECIALIST or
above.
Editing the user information
1
Press <Constant Setting> - [1 Control Constants] - [17 User Management] -
[3 Edit a registered user].
≫The registered user list screen is displayed.
2
Select the user whose information is to be edited, and press [Enter].
≫The information of the selected user is displayed.
3
After editing the user information, press f12 <Complete>.
1.2 Using the user management function
1.2 Using the user management function
1.2.1 Log-in operation
User must log into the robot controller to perform editing operations. There are the following three
ways to log in.
(1) Select R503 (Log-in) from the short-cut functions.
(2) Select <Service Utilities>-[33 User management]-[1.Log in]
(3) Allocate the function <Log in> (code 1503) to an f key and press the f key.
INFO.
When there is already any logged-in user, the user will be automatically
logged out.
Logging in
1
Perform one of the above three operations.
≫ The log-in input screen is displayed.
Enter the user ID, and the registered user name will be displayed in the user name
field.
2
Input the user ID and password in this order.
≫ If there are no problems with the authentication of the password, log-in is
completed, and the previous screen is restored.
IMPORTANT
If a user has forgotten the password, the password must be changed. For details on how
to change the password, refer to
“User information editing” in section 1.1.6 on
page 1-8.
USER NAME
f key
for log-in
3
If the user ID is not recognized in step 1 above, move the cursor to the [USER
NAME] button, and press [Enter].
≫ The screen which lists the registered users is displayed.
4
After selecting the user, press [Enter].
≫ The previous screen is restored, and the designated user is now selected.
1.2.2 Log-out operation
After finishing the editing operation, user must perform the log-out operation to leave the logged-in
status.
As with log-in, log-out can be performed in one of the following three ways.
(1) Select R504 (Log-out) from the short-cut functions.
(2) Select <Service Utilities>-[33 User management]-[2.Log out]
(3) Allocate the function <Log in> (code 1503) to an f key and press f key under the
logged-in status.
INFO.
f key <Log in>
The f key for <User log in> is indicated as
a key for log out under the logged-in status.
Automatic log-out
If the automatic log-out function is set to “enabled,” a user will automatically
be logged out when the non-operation time has reached the selected period
of time.
Logging out
1
Perform one of the above three operations.
≫The log-out screen is displayed.
2
Select [OK], and press [Enter].
≫After log-out, the previous screen is restored.
POINT
When log-out is initiated, the protection level returns to
subsequent editing operations. To proceed with editing again, the user needs to log in
BEGINNER, thus limiting the
1.2 Using the user management function
1.2.3 User information at log-in
If the user is logged in, an icon indicating ‘logged-in’ appears in the changeable status display
area. The user ID is displayed on the icon so that the logged-in user can be identified. When the
user logs out, the icon is cleared.
In the example given below, the user with the “001” user ID has logged in.
This section describes the steps for checking the user information at log-in and the steps for
changing the user information of a logged-in user.
Checking the information of the logged-in user
286
1
While the user is logged in, execute the System Environment short-cut (R286).
≫The information of the currently logged-in user is now displayed.
User ID
Log-in time
User name
Comment
Operator class
2
Press [Reset].
≫The previous screen is restored.
Changing the user information of the user who is logged in
505
1
While the user is logged in, execute the short-cut (R505) Edit own user
information.
2
To edit the information, press f12 <Edit>.
≫ The password confirmation screen now appears for authenticating the user.
Password
3
Input the password.
≫ The previous user information screen is displayed, and status in which the user
information can be edited is established.
4
Move the cursor to the item to be edited, and after editing, press f12
<Complete>.
Chapter 2 Edit logging
This chapter describes the edit logging function.
2.1 Concerning edit logging ...2-1
2.2 Referencing the edit logging ...2-2
2.2.1 Editor logging monitor displays ...2-2
2.2.2 Editor logging monitor functions ...2-7
2.1 Concerning edit logging
2.1 Concerning edit logging
The edit logging function, which is designed for maintenance purposes, makes it possible to initiate a speedy
recovery from logged information when an editing error has caused trouble in operation. It achieves this by
leaving a log of the changes made to the files and setting items edited by the users--that is to say, who made the
changes, when they were made, what changes were made and in what way they were made.
Only task programs and arc welding conditions are logged in the edit logging. With the arc welding conditions, the
editing of the arc welding conditions and arc welding constants are logged.
IMPORTANT
•
If edit logging data is to be returned to previous values, this must be done manually.
•
The edit logging function logs changes made by the editing operation of user.
Automatically changed data, e.g. deviation when using a sensor, is not to be logged in
the history..
Set the maximum numbers which can be acquired for the task program edit log and the edit log for the arc
welding conditions. The edit logging function can be disabled by setting the edit logging numbers to zero.
To set the function, the operator must have the qualifications level of
EXPERT or above.
The edit logging function is normally disabled. The function can be set to “Enabled” by operating as follows.
Enabling the edit logging function
1
Press <Constant Setting> - [24 Logging Data] - [5 Edit Logging Item].
≫ The edit logging setting screen is displayed.
Numerical
value
2
Enter the maximum number of the edit operations to be logged. A figure
selected from 0-10 can be entered in the hundreds digit field. When 0 is
input, the function is disabled.
IMPORTANT
If the entered maximum number of the edit operations to be logged is smaller than the
actual number of the edit operations already logged, older log data beyond the confines of
the maximum number will be deleted.
3
After the setting has been established, press f12 <Complete>.
2.2 Referencing the edit logging
The edit logging data can be referenced using the monitors. There are two editor logging monitors, each for a
different type of logging data. “61 Program editor logging” is used for task programs whereas “62 Arc welding
editor logging” is used for the arc welding conditions.
2.2.1 Editor logging monitor displays
Displaying the task program editor logging monitor
1
Press <Service Utilities> - [Monitor 1-4] - [61 Program editor logging].
≫ The task program editor logging monitor is displayed.
Editing type: Displayed in this column are the general descriptions which enable the
editing operations to be identified.(See Table 2.2.1.)
Task program,
Step number
2.2 Referencing the edit logging
Table 2.2.1 Editing types
Operation location
Display message
Description of operation
Recorded step
Operation for teaching movement command
Inserted step
Operation for adding movement command
Overwritten step
Operation for overwriting movement command
Modified position of
step
Operation for modifying position of movement command
Deleted step
Operation for deleting movement command or function command
Teached func step
Operation for teaching function command
Modified step
Operation for changing parameter of movement command
Undo
Undo operation after performing editing operation
Program editor
Redo
Redo operation after performing undo operation
Screen
Editor(Insert)
Insertion operation using screen editor
Screen Editor
(Modify)
Editing operation using screen editor
Program screen
editor
Screen Editor
(Delete)
Step deletion using screen editor
Copy file
Copying operation for program files
Delete file
Deletion operation for program files
File manager
Rename file
Renaming operation for program files
Condition/Speed
Program conversion menu no.1
Copy step
Program conversion menu no.2
Angle
Program conversion menu no.3
XYZ shift
Program conversion menu no.4
Tool
Program conversion menu no.5
Mirror image
Program conversion menu no.6
3D shift
Program conversion menu no.7
Language
Program conversion menu no.8
Point Shift
Program conversion menu no.9
Expansion/reduction Program conversion menu no.10
External axis shift
Program conversion menu no.11
Format Conversion
Program conversion menu no.12
Unit Conversion
Program conversion menu no.13
Pitch Copy & Shift
Program conversion menu no.16
Program converter
Multi Welding
Program conversion menu no.17
Create welding file
Creation operation for welding-related (welding, weaving, etc.) condition files
Delete welding file
Deletion operation for welding-related (welding, weaving, etc.) condition files
Edit welding file
Editing operation for existing welding-related condition data
Welding condition
editor
Online modification
of welding condition
On-line modification operation for welding condition data
Edit welding
constant data
Changing operation for welding-related constant settings
Create file
File creation operation for welding characteristic, welding condition databases, etc.
Copy file
File copying operation for welding characteristic, welding condition databases, etc.
Welding constants
Delete file
File deletion operation for welding characteristic, welding condition databases, etc.
Inserted record
Record addition operation for welding condition databases
Deleted record
Record deletion operation for welding condition databases
Welding constants
(welding condition
2
Using [up/down], bring the cursor to the log whose detailed information is to be
displayed, and press [Enter].
≫ The detailed information is displayed in the bottom half of the screen
.
Line 1: Detailed listing description
The items are displayed in the following sequence.
•
The user information is displayed only when the user management function
has been enabled.
Line 2: Guide message
The guide messages are displayed when the position data has been displayed. In
the example shown above, a guide message is not displayed, and a blank line is
shown.
Lines 3, 4: Pre-change and post-change values
When, as shown above, the system has a multiple number of mechanisms, all the
mechanism data is displayed when movement commands have been modified.
3
Press [Enter] again.
≫ The detailed information screen is closed.
2.2 Referencing the edit logging
Displaying the arc welding editor logging monitor
1
Press <Service Utilities> - [Monitor 1-4] - [62 Arc welding editor logging].
≫ The arc welding editor logging monitor is displayed.
Table 2.2.2 List of data types
Data type
Description
PRG
Program
AS/AE
Arc start condition, Arc end condition
WS Weaving
condition
RT
Arc retry condition
MOV
Robot operation condition
MOF
Multi-offset condition
RRS
Robot RS condition
ASM/AEM
Arc start condition in multipass welding
Arc end condition in multipass welding
ASMV/AEMV
Arc start in multipass welding
Arc end in multipass welding
(variables)
RS RS
condition
CON Welding
constants
Editing type
Refer to Table 2.2.1
Editing location
• Condition filenames in the case of condition files
• Task program names and step numbers in the
case of direct values
• Menu names in the case of constant settings
Data type
2
Using [up/down], bring the cursor to the log whose detailed information is to be
displayed, and press [Enter].
≫ The detailed information is displayed in the bottom half of the screen.
Line 1: Detailed listing description
The items are displayed in the following sequence.
•
The step numbers are displayed only when the edited data are direct values
rather than condition files.
•
The user information is displayed only when the user management function has
been enabled.
Line 2: Title of edited data
The names of the items displayed during editing are displayed.
Line 3: Pre-edited and post-edited values
The settings before and after editing are displayed. However, in the case of radio
buttons and combo boxes, the numbers starting from the first of the items
selected are displayed on the left as numerical values (counted from zero). On
the right, a message for the data selected at the time is displayed. An example is
shown on the left below.
However, “-” is displayed if the message is of a type which can be changed. The
example shown below on the right is a case in point.
3
Press [Enter] again.
≫ The detailed information screen is closed.
Title of edited data
Pre-change value
Post-change value
Detailed listing
description
2.2 Referencing the edit logging
2.2.2 Editor logging monitor functions
A number of different display methods are available for the editor logging monitors to make it
easier to analyze the edit logging concerned.
Before proceeding, change to the operator qualifications level of
USER or above.
Using the display selection function of the editor logging monitors
1
Select the editor logging monitor (task program or welding conditions), and
press [EDIT].
≫ The title bar of the editor logging monitor turns red, and a number of soft keys used
for the editor logging monitor are displayed.
1
For changing the items sorted
Use this key to change the items sorted in the edit logging. As the initial
value, the items are sorted in the date/time sequence. Each time the key is
pressed, the sorted items change as follows:
Date/time sequence
Program number sequence
User ID sequence
POINT
The user ID sequence can be selected only when the user
management function has been enabled.
2
For changing the sorting sequence
Use this key to switch the sorting between ascending and descending
order.
The sorting reference is based on the items which were set using key 1 .
3
For splitting the screen
Use this key to split the screen into the top half and bottom half.
5
6
1
2
3
4
4
For moving up/down
Use this key to move up or down when the screen has been split using key
4 .
5
For selecting the display
This f key is displayed only when the arc welding editor logging monitor is
used.
Use it to change the items whose edit logging is to be displayed. As the
initial value, all items are displayed. Each time this key is pressed, the
items to be displayed change as follows:
All items
Welding conditions
Welding constants
6
Clearing the edit logging
Use this key to clear all the edit logging information. (For this, the operator
must have the qualifications level of
EXPERT or above.)
2
Press [RESET/R].
Chapter 3 User Check
This section describes the user check function for notifying operators of the robot
inspection timing, parts replacement timing and other inspection-related
information.
3.1 User Check ...3-1
3.2 Setting the user check ...3-2
3.2.1 Setting up the check item...3-2
3.2.2 Allocating input/output signals...3-6
3.2.3 When reaching the inspection timing ...3-6
3.2.4 When check and part replacement are completed ...3-7
3.1 User Check
3.1 User Check
User check function is used to notify the operators of the inspection timing of the robot and the exchange timing
of the parts.
The check Items and the setting values to be checked can be freely set up to 8 types in each mechanism or arc
welding power supply.
For example, the setting such as “giving notice of the tip replacement when the time taken for the arc welding
reaches 100 min.” is possible. When reaching the specified inspection timing, the message which prompts the
operator to check is displayed on the teach pendant, and, at the same time, the user maintenance signal is
output to notify the operators of the inspection timing.
INFO.
This function corresponds to “System Maintenance Function” of conventional EX-C
series robot controller.
Change the operator qualification to EXPERT or higher in advance.
IMPORTANT
To output the user maintenance signal, the signal-allocation setting is required. As for
the set signal in this function, refer to “3.2.2 Allocating input/output signals”.
Checking for the check item is performed in 5 min-periods. For this reason, the notice
of the inspection requirement cannot be given at the time of reaching the inspection
timing. (refer to e.g.1)
The check time is updated at the timing of checking the check item. For this reason,
when the robot controller is powered off, the time during off-state of the controller
cannot be counted as the check time.
(refer to e.g.2)
E.g.1)
Even if the arc time reaches the
inspection timing at this point, the
notice cannot be given.
The notice of the inspection can be
given at the timing of “Checking items”.
E.g.2)
Even if the arc welding is performed
during this time, the arc time cannot be
counted.
The time to be checked such as the arc
time is updated at the timing of
“Checking items”.
Inspection period (5 min.)
Checking items
Checking items
3.2 Setting the user check
3.2.1 Setting up the check item
Follow the procedure below to configure the check item.
(1) Select the target of the check (“Mechanism” / “Arc welding”).
(2) Select the mechanism to be set, when the target of the check is “Mechanism”.
(In the case of one-mechanical configuration, no selection is required.)
(3) Select the arc welding power supply to be set, when the target of the check is “Arc
welding power supply”. (In the case of one-arc welding power supply configuration, no
selection is required.)
(4) Select the check item number. (Up to 8 types can be set)
(5) Set the message of the inspection timing. (E.g. Tip replacement)
(6) Select the suitable time category for the content of the inspection from the table below.
(7) Configure the setting value to be checked. (Inspection timing)
Table 3.2.1
Kind of check available when the target of the check is “Mechanism”
Kind of check
Contents
Calendar
The target number of months from the current date can be set.
For example, in the case of giving notice of the inspection timing in a year
from today.
Energizing
The accumulated time of the activated this controller can be set. The
value shall be set by the hour.
Servo ON
The accumulated time from the servo power-on to the servo power-off
can be set.
The value shall be set by the hour.
Operation
The accumulated value of time taken for the automatic operation can be
set.
The value shall be set by the hour.
Table 3.2.2 Kind of check available when the target of the check is “Arc welding power supply”
Kind of check
Contents
Calendar
The target number of months from the current date can be set.
For example, in the case of giving notice of the inspection timing in a year
from today.
Arc ON
The total hours of the accumulated welding time taken for the automatic
operation and the welding time during the check welding can be set. The
value shall be set by the minute.
Welding counts
The accumulated number of welding can be set in units of from the arc
start to the arc end.
Consumption of wire
The accumulated consumption of wire used in the welding can be set.
The value shall be set in units of Kg.
Note; this function can be set when the D-series welding power supply
without DA is selected.
INFO.
3.2 Setting the user check
Setting up the check item for the mechanism
1
Open <Service> - [25.Robot Diagnosis] - [5.User Check].
≫ The list screen of the user check items is displayed.
2
Select “Mechanism” in the Check object field. Then, select the mechanism to be
checked in [Unit / Mechanism].
≫ The selected mechanism No. is displayed on the f7 key.
3
Move the cursor to the content field and press [Enter].
≫ The setting screen of the user check items is displayed.
Table 3.2.3
Items
Details
Mechanism No.
The selected mechanism No. is displayed.
No
The check item No. is displayed.
Content
The check content is set as comment.
The set-up contents at this point are used for the message to
prompt the operator to check.
For example, in the case where the check content is set to
“annual inspection”, as shown below, the message is set in the
beginning of the check message and displayed on the teach
pendant, when reaching the inspection timing.
(Check message)
Note that press [ENABLE] + [Edit] to configure the settings. Edit
the check contents on the soft keyboard.
Check day
The date when the check complete procedure is performed is
displayed.
Last Modified
The date when the check content is modified is displayed.
Kind at time
Select the kind of time to be checked.
For details, refer to Table 3.2.1.
Set time (Remainder)
Set the setting value to be checked. (inspection timing)
The items other than “Calendar” in Kind of check field are set in
this process. The parenthetic value indicates the rest of hours for
the inspection timing.
Calendar
Set the setting value to be checked. (inspection timing)
The item, “Calendar”, in the Kind of check field is set in this
process. The parenthetic value indicates the date to be checked.
When this key is pressed, the inspection timing is reset.
In addition, this key is also used after the check is completed. For
details, refer to “3.2.4 When check and part replacement are
completed”.
4
Press f9 <Prev No> or f10 <Next No>, when changing to the different check item
No., and change the check item No.
5
Set the check content and press f12 <Complete>.
≫ The previous setting screen is returned.
The set check content is displayed in the content field.
【annual inspection】Exchange the axis. After that 0 clearing
of “Consumtion time until present”
3.2 Setting the user check
Setting up the check item for the arc welding
1
Open <Service> - [25.Robot Diagnosis] - [5.User Check].
≫ The list screen of the user check items is displayed.
2
Select “Welder” for Check object.
Then, move the cursor to the welder field to select the welding power supply to be
checked.
3
Move the cursor to the content field and press [Enter].
≫ The setting screen of the user check items is displayed.
Setting items are as follows.
Table 3.2.4 Details of the items
Items
Details
Welder
A selected arc welding power supply is displayed.
Kind at time
Select the kind of time to be checked.
For details, refer to Table 3.2.2.
4
Press f9 <Prev No> or f10 <Next No>, when changing to the different check item
No.
5
Set the check content and press f12 <Complete>.
≫ The previous setting screen is returned.
3.2.2 Allocating input/output signals
The basic I/O signals used in the user check function are as follows.
The I/O signals are used for the mechanism check and the arc welding power supply. “M1 to M9”
shown in the table below denotes the mechanism No. and “W1 to W4” denotes the arc welding
power supply No.
Those I/O signals are not allocated before shipment. If necessary to use them, refer to the
instruction manuals “SET UP” to allocate the signals.
Table 3.2.5 Input signal
Input signal name
Application
Function.
User chk complete 1 to 8
（M1 to M9）
Mechanism
User chk complete 1 to 8
（W1 to W4）
Arc welding power
supply
The inspection timing is reset for the next
checkup. The number from 1 to 8 defined
as the check item No. can be set in each
check item.
Table 3.2.6 Output signal
Input signal name
Application
Function.
User maintenance 1 to 8
（M1 to M9）
Mechanism
User maintenance 1 to 8
（W1 to W4）
Arc welding power
supply
The signal of the check item that reaches
the inspection timing is output. The
number from 1 to 8 defined as the check
item No. can be set in each check item.
3.2.3 When reaching the inspection timing
When the inspection items specified in advance have reached the inspection timing, the message
will appear on the Teach pendant. Also, the signals shown in the Table 3.2.6 are output.
The check item that reaches the inspection timing is highlighted in red on the list screen of user
check items.
Display of the check message
Display of the check items that reach the inspection timing
The set check contents
are displayed.
The items are
highlighted in red.
3.2 Setting the user check
3.2.4 When check and part replacement are completed
After completing the inspection operation, the corresponding user inspection signals for check are
to be reset, and the upcoming inspection timing is reconfigured.
Completing the inspection and the replacement of components, be sure to implement the
completion of inspection.
For the check complete procedure, there are two methods as follows.
(1) Manual operation
Perform the check complete procedure with the teach pendant on the setting screen of the
user check item.
(2) Input signal
Change the user chk complete signal set in each check item to ON.
User complete operation on the setting screen of user check item
1
Open [5.User Check] in <Service> - [25.Robot Diagnosis].
≫ The list screen of the user check items is displayed.
2
Select the check item to perform the complete procedure from the check items of 1
to 8, and press [Enter].
≫ The setting screen of the user check items is displayed.
3
Press f8 <Check Complete>.
≫ The following confirmation screen is displayed.
Chapter 4 Troubleshooting
This chapter describes the symptom and its measures on the failure code of
robot controller.
4.1 When failure has occurred...4-1
4.2 Concerning the failure details ...4-2
4.2.1 Failure category ...4-2
4.2.2 Concerning criticality codes and failure codes ...4-3
4.3 Concerning “System Failure”...4-4
4.3.1 Outline of “System Failure” ...4-4
4.3.2 How to recover and response to the failures...4-4
4.4 Recovery after failing of power down detection ...4-5
4.4.1 Recovery after failing of power down detection...4-5
4.4.2 Setting of start operation permission...4-5
4.5 Troubleshooting...4-7
4.5.1 Assumed cause of each error code...4-7
4.5.2 Assumed cause of each phenomenon ... 4-11
4.6 Displaying the failure log ...4-14
4.6.1 Function of the failure log monitor...4-15
4.6.2 Settings regarding the failure log ...4-16
4.6.3 Failure filtering function ...4-20
4.6.4 Displaying the system failure log...4-23
4.6.5 Frequency of the failure occurrence...4-24
4.7 Failure list ...4-27
These white letters will not be printed. Do not delete these letters.
4.1 When failure has occurred
4.1 When failure has occurred
When a failure has occurred in the robot, the failure monitor starts, and the details of the failure (name of its
category, date/time of its occurrence, description and remedial action) are displayed on the teach pendant.
(1)
(2)
(3)
(4)
(5)
(7)
(6)
(1)
Failure category
The name of the failure category appears here.
(2)
Failure code and cause
The failure code and cause appear here.
The failure code is alphanumerically expressed. In the example of
the screen shown above, “A2101” is the failure code.
(3)
Details and remedial action
The details of the failure and the remedial action to be taken appear
here.
Use the remedial action displayed here as a reference, and
eliminate the cause of the failure.
(4)
Release method
The method used to release the failure display appears here.
When all the contents of (3) and (4) do not appear in the display
area, scroll the screen using [up or down].
(5)
Number of failure incidents
The figure on the right indicates the number of failure incidents
which have occurred simultaneously. Only one failure incident is
displayed on the screen at one time.
To view other types of trouble, press [ENABLE] and [up or down].
(6)
Date/time of occurrence
The date and time of the failure occurrence appear here.
(7) F11<Trouble
Shooting>
When a failure that requires e.g. parts inspection or parts
replacement occurs, this <Trouble Shooting> will show up here.
(Not all of the errors support this) When this key is pressed, the
inspection/part replacement procedure will be displayed.(Visual
Maintenance Support Function)
(8)
f12 <Failure Reset>
Press this to release the failure display.
The failure display can also be released by pressing [RESET/R]
twice.
4.2 Concerning the failure details
4.2.1 Failure category
The failure categories which are displayed at (1) on the previous page are established to enable
where the failure has occurred to be pinpointed to some extent.
Table 4.2.1 Failure category
Failure category
Main failure
Emergency stop failure
Emergency stop triggered by input from overrun, shock sensor, etc.
Control sequence
failure
Failure detected by monitoring of control systems such as magnet switches and circuit
protectors, etc.
CPU board failure
Watchdog timer detection or other CPU board-related failure occurrence.
Servo failure
Failure detected by IPM drive unit software.
Amplifier unit failure
Failure detected by IPM drive unit hardware.
Encoder failure
Failure detected by internal of encoder.
Teach pendant failure
Failure detected by teach pendant.
PLC failure
Failure detected by PLC.
User failure
Failure defined by the operator
Operation failure
Failure caused by an operation error made by operator.
Spot welding failure
Failure inherent to “spot welding function” (but not included above)
Arc welding failure
Failure inherent to “arc welding function” (but not included above)
FieldBus failure
Failure inherent to "FieldBus function" (but not included above)
Shift failure
Failure inherent to "Shift function" (but not included above)
Auto Calibration failure
Failure inherent to "Automatic Calibration function" (but not included above)
Sealing failure
Failure inherent to "Sealing function" (but not included above)
Vision sensor failure
Failure inherent to "Vision sensor function" (but not included above)
FLEXhand failure
Failure inherent to "FLEXhand function" (but not included above)
Preventive
maintenance message
Failure inherent to "Preventive maintenance function" (but not included above)
4.2 Concerning the failure details
4.2.2 Concerning criticality codes and failure codes
The failure codes displayed at (2) on the previous page are expressed using the following format.
[Example] Control sequence failure code E1103
E
1
1
0
3
(A)
(B)
(A) Criticality codes
The failure detected by the robot is classified into three types by their level of criticality.
Table 4.2.2 Criticality codes
Type of failure
Details
E (errors)
Failure caused by parts failure or internal data failure which prohibits continued operation
until the cause of the failure is eliminated, and failure which may potentially injure the
operator or damage the robot system if operation is continued are classified as E
(errors).
If E (error) occurs during the auto operation, the robot system servo is turned off.
A (alarms)
Failure which may lead to an error at a future point in time, failure which must be
remedied now or failure requiring simple operations, checks and/or remedial action
before robot operation or movements are continued even though it may not potentially
injure the operator or damage the robot system are classified as A (alarms).
If A (alarm) occurs during the auto operation, the robot system servo remains on,
stopping temporarily.
I (Information)
Failure requiring that the operator and ambient devices be informed of the occurrence of
irregularities even though they will not interfere with continued robot operations or
movements is classified as I (information). Information may sometimes be conveyed not
when a failure has occurred but when the robot is operating normally.
If I (information) occurs during the auto operation, robot system displays the message on
the teach pendant, operating continuously.
(B) Failure codes
4.3 Concerning “System Failure”
4.3.1 Outline of “System Failure”
The function “System Failure” is to stop the system safely when the software has detected
unrecoverable errors. The errors may stem from the hardware failures such as CPU or memory
defects and software failures.
Display example of teach pendant when “System Failure” occurred
4.3.2 How to recover and response to the failures
When this error happens, the robot makes an emergency stop, which will disable all the
following operation.
Therefore, the recovering measures needs to be taken as follows.
【
How to recover the failures
】
Shut off the robot controller, and turn on the power again.
【
How to response to the failures
】
Please make a contact to our service engineers with the details of errors such as;
“Operation you have done”, “Operating situation”, and “Error Code”, “Flag”,
“Address”, “Stack” indicated on Teach pendant.
4.4 Recovery after failing of power down detection
4.4 Recovery after failing of power down detection
4.4.1 Recovery after failing of power down detection
If power down detection failed, alarm A0004 ”Data was not saved correctly when power down.” is detected at
the timing of power on, and program / step number is cleared (not selected). In case that “Motors/ON/Start sel.
source” is set to “Controller”, program or step number must be selected by teach pendant before initiating
playback operation for safety.
On software version FDV03.28 or later, this safety function is enabled even when “Motors/ON/Start sel. source”
is set to “External”. If playback operation is tried without selecting step, error E2518
“Step number not
designated
” is detected and playback operation is denied. This error detection is functioning from shipment, so it
is unnecessary to change this setting by following to the procedure written here.
In case of multi-unit specification, program selection or step selection is necessary for each unit.
As an exception, in case that unit is started by CALL or FORK functions, this operation is unnecessary because
started unit program is initiated from step 0.
4.4.2 Setting of start operation permission
When power down detection is failed, it is selectable to permit or not to permit start operation. This error
detection is functioning from shipment, so it is unnecessary to change this setting.
1
Select TEACH mode.
2
Set the operator qualification to EXPERT or higher.
＋
3
Press <Constant setting> - [5 Operation Constants] - [1 Operation Condition] and
press [Enter].
＋
4
Align cursor on [37 Start permission after A004] and select one by [Enable] +
[Left/Right] key.
Candidates
Explanation
After step set
When power down detection is failed,
Step number must be selected (step set operation)
before initiating playback operation for safety.
If playback operation is tried without selecting step,
error E2518
“Step number not designated” is detected
and playback operation is denied.
No need
When power down detection is failed,
playback operation is permitted without selecting step.
5
Press F12 <Complete>.
≫ Setting is stored to memory.
4.5 Troubleshooting
4.5 Troubleshooting
Perform inspection and part replacement safely, observing the following instructions.
4.5.1 Assumed cause of each error code
When an error occurs, you can estimate the part which causes the error from the error code.
In case of an error, please investigate the cause in decreasing order of the possibility, using this table.
Table 4.5.1 Assumed cause of each error code
Error code
Power u
nit
Multi power Supply u
nit
CPU boar
d
Seque
nce b
oar
d
Riser boa
rd
Arc I/F board
I/O board
IPM drive unit
Regen
erative r
esistor
Control cable (
rob
ot
wiring)
Manipulator & load
Motor & encod
er
Reduction ge
ar
Teac
h pend
ant
Operation
pa
ne
l / box
Jig controller
Primary pow
er s
uppl
y &
ambient temp.
None
No TP indication
○
◎
◎
◎
○
◎
◎
4
The automatic saving function at
the timing of the power failure
detection (or controller power
OFF operation) failed.
◎
◎
◎
○
△
12
The robot cannot reach the
recorded point.
◎
◎
○
○
21
Abnormal servo tracking
○
◎
○
○
◎
22
Position Deviation error
○
◎
○
○
24
Servo CPU stop
○
◎
25
Encoder Bit jump
●
●
●
26
Interference detected
○
○
○
○
27
Encoder data change after stop
●
●
●
28
Low voltage of motor power
◎
◎
△
◎
29
Encoder absolute data error
◎
30
Encoder absolute data failure
◎
31
Motor rotation too fast when
turning the motors ON
◎
32
Over current
○
○
◎
○
38
Over load
○
○
◎
39
Over rotation
○
○
○
40
The abnormalities in CPU in a T/P
◎
42
Over temperature of motor
○
○
◎
○
43
Over speed
○
◎
44
Over voltage of motor power
◎
◎
Error code
Power u
nit
Multi power Supply u
nit
CPU boar
d
Seque
nce b
oar
d
Riser boa
rd
Arc I/F board
I/O board
IPM drive unit
Regen
erative r
esistor
Control cable (
rob
ot
wiring)
Manipulator & load
Motor & encod
er
Reduction ge
ar
Teac
h pend
ant
Operation
pa
ne
l / box
Jig controller
Primary pow
er s
uppl
y &
ambient temp.
51
Encoder data
transmission failure
●
●
●
52
Encoder battery error
◎
○
54
Positional deviation
◎
◎
55
Encoder battery charge
low
○
○
◎
57
Encoder count status
failure
◎
62
Emergency stop was
shortly input or Magnetic
SW was cut off.
○
○
○
○
○
△
○
64
Drive unit power failure
◎
65
Over travel limit switch
activated
○
◎
66
Low voltage of brake
power
◎
72
Drive unit IPM failure
◎
◎
○
74
Motor regeneration circuit
fault
○
◎
◎
78
CPU board power fault.
○
◎
79
CPU board temperature
fault.
○
◎
◎
80
CPU board power fault.
◎
◎
○
81
CPU board battery failure
◎
106
The motors are not ON.
○
◎
○
◎
116
TP connect failure
○
◎
◎
119
The T/P connection is
abnormal.
○
◎
177
Primary power supply
fault.
◎
○
○
◎
379
Safety plug is not inserted or the state of safety plug signal haschanged in teach mode.
