R-30iB Basic Operator Manual

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OPERATOR'S MANUAL (Basic Operation)

B-83284EN/04

R-30+B/ R-30+B Mate CONTROLLER

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Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content.

• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and

Foreign Trade Law”. The export from Japan may be subject to an export license by the

government of Japan.

Further, re-export to another country may be subject to the license of the government of

the country from where the product is re-exported. Furthermore, the product may also be

controlled by re-export regulations of the United States government.

Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.

However, we cannot describe all the matters which must not be done, or which cannot be

done, because there are so many possibilities.

Therefore, matters which are not especially described as possible in this manual should be

regarded as “impossible”.

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B-83284EN/04 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

Thank you for purchasing FANUC Robot.

This chapter describes the precautions which must be observed to ensure the safe use of the robot. Before attempting to use the robot, be sure to read this chapter thoroughly.

Before using the functions related to robot operation, read the relevant operator's manual to become familiar with those functions.

If any description in this chapter differs from that in the other part of this manual, the description given in this chapter shall take precedence.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell.

In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 WORKING PERSON

The personnel can be classified as follows.

Operator:

• Turns robot controller power ON/OFF

• Starts robot program from operator’s panel

Programmer or teaching operator:

• Operates the robot

• Teaches robot inside the safety fence

Maintenance engineer:

• Operates the robot

• Teaches robot inside the safety fence

• Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence.

- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc.

- To work inside the fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions.

- Use adequate clothing or uniforms during system operation - Wear safety shoes

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2 DEFINITION OF WARNING, CAUTION AND

NOTE

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "Warning" or "Caution" according to its severity. Supplementary information is indicated by "Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use the robots.

WARNING

Applied when there is a danger of the user being injured or when there is a

danger of both the user being injured and the equipment being damaged if the

approved procedure is not observed.

CAUTION

Applied when there is a danger of the equipment being damaged, if the

approved procedure is not observed.

NOTE

Notes are used to indicate supplementary information other than Warnings and

Cautions.

• Read this manual carefully, and store it in a sales place.

3 WORKING PERSON SAFETY

Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety.

(1) Have the robot system working persons attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see Fig.3 (a) and Fig.3 (b).

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(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area.

(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that stops the robot when a working person enters the work area.

(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the power of the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot (10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation

with gloved fingers could cause an operation error.

(11) Programs, system variables, and other information can be saved on memory card or USB memories. Be sure to save the data periodically in case the data is lost in an accident.

(12) The robot should be transported and installed by accurately following the procedures recommended by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers.

(13) In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot.

(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation.

(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured.

- Avoid using the robot in a flammable environment. - Avoid using the robot in an explosive environment. - Avoid using the robot in an environment full of radiation. - Avoid using the robot under water or at high humidity. - Avoid using the robot to carry a person or animal.

- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)

(16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong connection.

(17) When preparing trestle, please consider security for installation and maintenance work in high place according to Fig.3 (c). Please consider footstep and safety bolt mounting position.

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RM1 Motor power/brake RP1 Pulsecoder RI/RO,XHBK,XROT EARTH Safety fence

Interlocking device and safety plug that are activated if the gate is opened.

Fig. 3 (a) Safety fence and safety gate

Dual chain Single chain Panel board FENCE1 FENCE2 Panel board EAS1 EAS11 EAS2 EAS21 （Note） In case of R-30iA

Terminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2 are provided on the operation box or on the terminal block of the printed circuit boar d.

In case of R-30iA Mate

Terminals EAS1,EAS11,EAS2,EAS21 are provided on the emergency stop board or connector panel. (in case of Open air type)

Termianls FENCE1,FENCE2 ar e provided on the emergency stop board.

Refer to controller maintenance manual for details. Emergency stop board

or Panel board (Note)

In case of R-30iB, R-30iB Mate

Terminals EAS1,EAS11,EAS2,EAS21 are provided on the emergency stop board.

Refer to the ELECTRICAL CONNCETIONS Chapter of CONNECTION of

R-30iB controller maintenance manual (B-83195EN) or R-30iB Mate controller maintenance manual (B-83525EN) for details.

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Steps

Hook for safety belt Fence

Trestle Footstep

for maintenance

Fig.3 (c) Footstep for maintenance

3.1 OPERATOR SAFETY

The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators.

(1) If you do not have to operate the robot, turn off the power of the robot controller or press the EMERGENCY STOP button, and then proceed with necessary work.

(2) Operate the robot system at a location outside of the safety fence

(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the work area unexpectedly and to prevent the worker from entering a dangerous area.

(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

Dual chain

Single chain

（Note）

Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2. In case of R-30iA

EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board. In case of R-30iA Mate

EES1,EES11,EES2,EES21　are on the emergency stop board or connector panel (in case of Open air type).

EMGIN1,EMGIN2　are on the emergency stop board. Refer to the maintenance manual of the controller for details. External stop button

Panel board EMGIN1 EMGIN2 Panel board EES1 EES11 EES2 EES21

External stop button

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Connect EES1 and EES11, EES2 and EES21 In case R-30iB, R-30iB Mate

EES1,EES11,EES2,EES21 are on the emergenc y stop board Refer to the ELECTRICAL CONNCETIONS Chapter of CONNECTION of

R-30iB controller maintenance manual (B-83195EN) or R-30iB Mate controller maintenance manual (B-83525EN) for details.

Emergency stop boa rd o r Pane l boa rd

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3.2 SAFETY OF THE PROGRAMMER

While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the safety of the teach pendant operator especially.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal

operating condition.

(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area.

(4) The programmer must be extremely careful not to let anyone else enter the robot work area.

(5) Programming should be done outside the area of the safety fence as far as possible. If programming needs to be done in the area of the safety fence, the programmer should take the following precautions:

－ Before entering the area of the safety fence, ensure that there is no risk of dangerous situations in the area.

－ Be prepared to press the emergency stop button whenever necessary. － Robot motions should be made at low speeds.

－ Before starting programming, check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to the user.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence.

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows:

(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type) when pressed.

(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting status.

(a) Disable: The DEADMAN switch is disabled.

(b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the operator presses the switch strongly.

Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot stops immediately.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000 times per year.

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B-83284EN/04 SAFETY PRECAUTIONS The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software.

In case of R-30iB Controller

Mode Teach pendant enable switch

Software remote condition

Teach pendant Operator panel Peripheral device

Local Not allowed Not allowed Not allowed On

Remote Not allowed Not allowed Not allowed Local Not allowed Allowed to start Not allowed AUTO

mode

Off

Remote Not allowed Not allowed Allowed to start Local Allowed to start Not allowed Not allowed On

Remote Allowed to start Not allowed Not allowed Local Not allowed Not allowed Not allowed T1, T2

mode

Off

Remote Not allowed Not allowed Not allowed

T1,T2 mode:DEADMAN switch is effective.

(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and that there are no abnormal conditions in the robot work area.

(7) When a program is completed, be sure to carry out a test operation according to the procedure below.

(a) Run the program for at least one operation cycle in the single step mode at low speed.

(b) Run the program for at least one operation cycle in the continuous operation mode at low speed.

(c) Run the program for one operation cycle in the continuous operation mode at the intermediate speed and check that no abnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in the continuous operation mode at the normal operating speed and check that the system operates automatically without trouble.

(e) After checking the completeness of the program through the test operation above, execute it in the automatic operation mode.

(8) While operating the system in the automatic operation mode, the teach pendant operator should leave the robot work area.

3.3 SAFETY OF THE MAINTENANCE ENGINEER

For the safety of maintenance engineer personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area.

(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during maintenance operations. Therefore, for any maintenance operation, the robot and the system should be put into the power-off state. If necessary, a lock should be in place in order to prevent any other person from turning on the robot and/or the system. In case maintenance needs to be executed in the power-on state, the emergency stop button must be pressed.

(3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.

(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire system in order to make sure no dangerous situations exist. In case the worker needs to enter the safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status must be carefully monitored.

(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and the pressure in the piping should be reduced to zero.

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(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition.

(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.

(8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working nearby, make certain that their escape path is not obstructed.

(9) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such as belt conveyor, pay careful attention to its motion.

(10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.

(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an accident may occur, causing damage to the robot and injury to the worker.

(12) When replacing or reinstalling components, take care to prevent foreign material from entering the system.

(13) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock.

If there are two cabinets, turn off the both circuit breaker.

(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire.

(15) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal. (16) When a motor or brake is removed, the robot arm should be supported with a crane or other

equipment beforehand so that the arm would not fall during the removal.

(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls.

(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated state, the worker should wear heat-resistant gloves or use other protective tools.

－ Servo motor

－ Inside the controller － Reducer

－ Gearbox － Wrist unit

(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause any danger.

(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to protect maintenance workers from excessive load. Otherwise, the maintenance workers would be severely injured.

(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot would be adversely affected. In addition, a misstep can cause injury to the worker.

(22) When performing maintenance work in high place, secure a footstep and wear safety belt.

(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the floor around the robot and within the safety fence.

(24) When a part is replaced, all bolts and other related components should put back into their original places. A careful check must be given to ensure that no components are missing or left not mounted. (25) In case robot motion is required during maintenance, the following precautions should be taken :

- Foresee an escape route. And during the maintenance motion itself, monitor continuously the whole system so that your escape route will not become blocked by the robot, or by peripheral equipment.

- Always pay attention to potentially dangerous situations, and be prepared to press the emergency stop button whenever necessary.

(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller maintenance manual.) A failure to do the periodical inspection can adversely affect the performance

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(27) After a part is replaced, a test operation should be given for the robot according to a predetermined method. (See TESTING section of “R-30iB/R-30iB Mate Controller operator’s manual (Basic Operation)”.) During the test operation, the maintenance staff should work outside the safety fence.

4 SAFETY OF THE TOOLS AND

PERIPHERAL DEVICES

4.1 PRECAUTIONS IN PROGRAMMING

(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received.

(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal.

(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

4.2 PRECAUTIONS FOR MECHANISM

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of grease, water, and dust.

(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.

(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does not strike against its peripheral devices or tools.

(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not kept, unexpected troubles might occur.

• Use mechanical unit cable that have required user interface. • Don’t add user cable or hose to inside of mechanical unit.

• Please do not obstruct the movement of the mechanical unit cable when cables are added to outside of mechanical unit.

• In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.

• Please do not interfere with the other parts of mechanical unit when install equipments in the robot.

(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid the system construction that power-off stop would be operated routinely. (Refer to bad case example.) Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type.)

(Bad case example)

• Whenever poor product is generated, a line stops by emergency stop.

• When alteration was necessary, safety switch is operated by opening safety fence and power-off stop is executed for the robot during operation.

• An operator pushes the emergency stop button frequently, and a line stops.

• An area sensor or a mat switch connected to safety signal operate routinely and power-off stop is executed for the robot.

(6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. The frequent urgent stop by alarm causes the trouble of the robot, too. So remove the causes of the alarm.

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5 SAFETY OF THE ROBOT MECHANISM

5.1 PRECAUTIONS IN OPERATION

(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality.

(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

5.2 PRECAUTIONS IN PROGRAMMING

(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere with each other.

(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the motion so that it starts from the origin and terminates at the origin.

Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

5.3 PRECAUTIONS FOR MECHANISMS

(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water, and dust.

5.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER

IN EMERGENCY OR ABNORMAL SITUATIONS

For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can be used to move the robot axes without drive power.

Please refer to controller maintenance manual and mechanical unit operator’s manual for using method of brake release unit and method of supporting robot.

6 SAFETY OF THE END EFFECTOR

6.1 PRECAUTIONS IN PROGRAMMING

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

7 STOP TYPE OF ROBOT

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Power-Off Stop (Category 0 following IEC 60204-1)

Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is moving, and the motion path of the deceleration is uncontrolled.

The following processing is performed at Power-Off stop. - An alarm is generated and servo power is turned off.

- The robot operation is stopped immediately. Execution of the program is paused.

Controlled stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off. The following processing is performed at Controlled stop.

- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the program is paused.

- An alarm is generated and servo power is turned off.

Hold (Category 2 following IEC 60204-1)

The robot is decelerated until it stops, and servo power remains on. The following processing is performed at Hold.

- The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING

The stopping distance and stopping time of Controlled stop are longer than the

stopping distance and stopping time of Power-Off stop. A risk assessment for

the whole robot system, which takes into consideration the increased stopping

distance and stopping time, is necessary when Controlled stop is used.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is different according to the controller type or option configuration.

There are the following 3 Stop patterns.

Stop pattern Mode Emergency stop button External Emergency stop

FENCE open SVOFF input Servo disconnect

AUTO P-Stop P-Stop C-Stop C-Stop P-Stop

A T1 P-Stop P-Stop - C-Stop P-Stop

T2 P-Stop P-Stop - C-Stop P-Stop

AUTO P-Stop P-Stop P-Stop P-Stop P-Stop

B T1 P-Stop P-Stop - P-Stop P-Stop

T2 P-Stop P-Stop - P-Stop P-Stop

AUTO C-Stop C-Stop C-Stop C-Stop C-Stop

C T1 P-Stop P-Stop - C-Stop P-Stop

T2 P-Stop P-Stop - C-Stop P-Stop

P-Stop: Power-Off stop C-Stop: Controlled stop -: Disable

The following table indicates the Stop pattern according to the controller type or option configuration.

Option R-30iB/ R-30iB Mate

Standard A (*)

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(*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF input. The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer to "Software version" in operator's manual of controller for the detail of software version screen.

"Controlled stop by E-Stop" option

When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following alarms becomes

Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is the normal operation of the system.

Alarm Condition

SRVO-001 Operator panel E-stop Operator panel emergency stop is pressed. SRVO-002 Teach pendant E-stop Teach pendant emergency stop is pressed.

SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is open.

SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF. SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:

- In Controlled stop, the robot is stopped on the program path. This function is effective for a system where the robot can interfere with other devices if it deviates from the program path.

- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.

- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the operator's manual of a particular robot model for the data of stopping distance and stopping time. When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING

The stopping distance and stopping time of Controlled stop are longer than the

stopping distance and stopping time of Power-Off stop. A risk assessment for

the whole robot system, which takes into consideration the increased stopping

distance and stopping time, is necessary when this option is loaded.

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B-83284EN/04

SAFETY PRECAUTIONS...s-1

1 INTRODUCTION ... 1

1.1 MANUAL

PLAN ... 1

2 OVERVIEW ... 4

2.1 APPLICATION

TOOL SOFTWARE ... 5

2.1.1 System Setting ...5

2.1.2 Jog Feed of the Robot...5

2.1.3 Program ...5

2.1.4 Test Operation (Test Execution) ...6

2.1.5 Automatic Operation (Operation Execution) ...6

2.2 ROBOT... 6

2.3 CONTROLLER ... 7

2.3.1 Teach Pendant ...9 2.3.2 Operator Panel ...27 2.3.3 Remote Controller ...28 2.3.4 CRT/KB...28 2.3.5 Communication ...28 2.3.6 Input/Output ...29 2.3.7 Peripheral I/O ...29

2.3.8 Motion of the Robot ...29

2.3.9 Emergency Stop Devices...29

2.3.10 Extended Axis ...30

3 SETTING UP THE ROBOT SYSTEM ... 31

3.1 I/O... 31

3.1.1 Digital I/O...42 3.1.2 Group I/O ...45 3.1.3 Analog I/O...48

3.2 ROBOT I/O ... 51

3.3 PERIPHERAL I/O ... 53

3.4 OPERATOR’S PANEL I/O ... 61

3.5 I/O

LINK

SCREEN ... 63

3.5.1 I/O Link List Screen ...63

3.5.2 Model B Unit List Screen...64

3.5.3 Signal Count Setting Screen...65

3.6 I/O

CONNECTION FUNCTION ... 66

3.7 SIMULATED

INPUT SKIP FUNCTION ... 69

3.8 SETTING

AUTOMATIC OPERATION ... 70

3.8.1 Robot Service Request (RSR) ...72

3.8.2 Program Number Selection (PNS) ...75

3.8.3 STYLE ...78

3.8.4 Prog Select Screen...81

3.8.5 Cell Interface I/O...87

3.8.6 Custom I/O ...90

3.9 SETTING

COORDINATE SYSTEMS ... 92

3.9.1 Setting a Tool Coordinate System...94

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3.9.3 Setting a Jog Coordinate System...113

3.9.4 Setting a Cell Coordinate System...117

3.9.5 Setting a Cell Floor...119

3.10 SETTING A REFERENCE POSITION... 120

3.11 JOINT

OPERATING AREA ... 123

3.12 USER

ALARM ... 124

3.13 VARIABLE

AXIS AREAS ... 126

3.14 INTERFERENCE

PREVENTION AREA FUNCTION... 127

3.15 SYSTEM

CONFIG MENU ... 130

3.16 SETTING THE GENERAL ITEMS ... 138

3.17 PAYLOAD

SETTING ... 140

3.18 OTHER

SETTINGS ... 143

4 PROGRAM

STRUCTURE ... 144

4.1 PROGRAM

DETAIL INFORMATION... 146

4.1.1 Program Name...146 4.1.2 Program Comment...147 4.1.3 Subtype...147 4.1.4 Group Mask...148 4.1.5 Write Protection ...148 4.1.6 Interruption Disable...148 4.1.7 Stack Size ...149

4.2 LINE NUMBER, PROGRAM END SYMBOL, AND ARGUMENT ... 150

4.3 MOTION

INSTRUCTIONS ... 152

4.3.1 Motion Format...153

4.3.2 Position Data ...158

4.3.3 Feed Rate...163

4.3.4 Positioning Path...165

4.3.5 Additional Motion Instructions ...166

4.4 PALLETIZING

INSTRUCTIONS ... 178

4.4.1 Palletizing Instruction...178

4.4.2 Palletizing Motion Instruction...179

4.4.3 Palletizing End Instruction ...179

4.5 REGISTER

INSTRUCTIONS... 179

4.5.1 Register Instructions...180

4.5.2 Position Register Instructions...181

4.5.3 Position Register Axis Instructions ...182

4.5.4 Arithmetic Palletizing Register Instructions...185

4.5.5 String Register, String Instructions ...186

4.6 I/O

INSTRUCTIONS ... 188

4.6.1 Digital I/O Instructions...189

4.6.2 Robot I/O Instructions ...190

4.6.3 Analog I/O Instructions ...191

4.6.4 Group I/O Instruction ...192

4.7 BRANCH

INSTRUCTIONS... 192

4.7.1 Label Instruction...193

4.7.2 Program End Instruction ...193

4.7.3 Unconditional Branch Instructions...193

4.7.4 Conditional Branch Instructions...194

4.7.5 Arguments ...198

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4.9 SKIP

CONDITION INSTRUCTION ... 210

4.10 PAYLOAD

INSTRUCTION ... 212

4.11 OFFSET

CONDITION INSTRUCTION ... 213

4.12 TOOL OFFSET CONDITION INSTRUCTIONS ... 214

4.13 FRAME

INSTRUCTIONS ... 215

4.14 PROGRAM

CONTROL INSTRUCTIONS ... 216

4.14.1 Pause Instruction ...216

4.14.2 Abort Instruction ...217

4.15 OTHER

INSTRUCTIONS ... 217

4.15.1 RSR Instruction ...217

4.15.2 User Alarm Instruction ...218

4.15.3 Timer Instruction ...218

4.15.4 Override Instruction ...219

4.15.5 Comment Instruction ...219

4.15.6 Multi-language Comment Instruction ...219

4.15.7 Message Instruction...220

4.15.8 Parameter Instruction...220

4.15.9 Maximum Speed Instructions...221

4.16 MULTIAXIS

CONTROL INSTRUCTIONS ... 222

4.16.1 Program Execution Instruction...222

4.17 OPERATION

GROUP INSTRUCTIONS... 222

4.17.1 Asynchronous Operation Group Instruction ...223

4.17.2 Synchronous Operation Group Instruction...223

4.18 FOR/ENDFOR

INSTRUCTION... 224

4.18.1 FOR Statement ...224

4.18.2 ENDFOR Statement ...224

4.18.3 FOR/ENDFOR Statement Combination ...225

4.18.4 Backward Execution of FOR/ENDFOR Statement...227

4.18.5 Examples of FOR/ENDFOR Statement Execution ...227

4.18.6 Alarms of FOR/ENDFOR Statement ...231

4.19 MIXED

LOGIC

INSTRUCTION... 232

4.20 DIAGNOSIS

INSTRUCTION ... 236

5 PROGRAMMING... 237

5.1 TIPS ON EFFECTIVE PROGRAMMING ... 238

5.1.1 Motion Instructions ...238

5.1.2 Predefined Position...240

5.2 TURNING ON THE POWER AND JOG FEED ... 241

5.2.1 Turning On the Power and Turning Off the Power ...241

5.2.2 Three-Mode Switch ...242

5.2.3 Moving the Robot by Jog Feed ...246

5.3 CREATING

A

PROGRAM ... 257

5.3.1 Registering a Program ...258

5.3.2 Changing a Standard Motion Instruction ...262

5.3.3 Teaching a Motion Instruction ...265

5.3.4 Teaching an Additional Motion Instruction ...267

5.3.5 Teaching a Control Instruction...270

5.3.6 TP Start Prohibition...287

5.4 CHANGING

A

PROGRAM ... 289

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5.4.2 Changing a Motion Instruction...290

5.4.3 Changing a Control Instruction ...301

5.4.4 Program Edit Instructions...302

5.5 PROGRAM

OPERATION ... 323

5.5.1 Changing Program Information...323

5.6 BACKGROUND

EDITING ... 327

5.7 SINGULAR

POINT

CHECK FUNCTION ... 341

5.8 OTHER

EDITING FUNCTION ... 342

5.8.1 Auto Position Renumbering ...342

5.8.2 Fixed Program Name...343

5.8.3 Filtered Program List...343

5.8.3.1 Method to use the original program name specified in the system configuration menu as the head of the string ... 343

5.8.3.2 Method to register 6 or more strings as the head of string... 344

6 EXECUTING

A

PROGRAM... 346

6.1 PROGRAM

HALT

AND RECOVERY ... 346

6.1.1 Halt by an Emergency Stop and Recovery...347

6.1.2 Halt by a Hold and Recovery ...348

6.1.3 Halt Caused by an Alarm ...349

6.2 EXECUTING

A

PROGRAM ... 352

6.2.1 Starting a Program...353

6.2.2 Robot Motion ...353

6.2.3 Resuming a Program ...356

6.3 TESTING ... 360

6.3.1 Specifying Test Execution...361

6.3.2 Step Test ...362

6.3.3 Continuous Test...366

6.3.4 Program Look/Monitor...368

6.4 MANUAL I/O CONTROL ... 369

6.4.1 Forced Output...369

6.4.2 Simulated I/O ...371

6.4.3 Wait Release...372

6.5 OPERATING

THE

HAND MANUALLY ... 372

6.6 AUTOMATIC

OPERATION ... 373

6.6.1 Automatic Operation by Robot Start Request (RSR)...374

6.6.2 Automatic Operation with Program Number Selection (PNS)...375

6.6.3 External Override Selection Function ...375

6.7 ONLINE

POSITION MODIFICATION ... 377

7 STATUS

DISPLAY ... 383

7.1 LEDS ON THE TEACH PENDANT... 383

7.2 USER

SCREEN... 385

7.3 REGISTERS ... 385

7.4 POSITION

REGISTERS ... 386

7.5 PALLETIZING

REGISTERS ... 389

7.6 STRING

REGISTERS ... 390

7.7 4D

GRAPHICS ... 392

7.7.1 4D GRAPHICS Display ...392 7.7.1.1 Graphic models... 393 7.7.1.2 Operation procedure ... 393

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7.8 SYSTEM

VARIABLES ... 398

7.9 PROGRAM

TIMER ... 400

7.10 SYSTEM

TIMER... 402

7.11 EXECUTION

HISTORY ... 403

7.12 MEMORY USE STATUS DISPLAY ... 404

7.13 STOP

SIGNAL... 405

7.14 PROGRAM

STATUS ... 407

7.15 POWER

CONSUMPTION MONITOR ... 408

8 FILE

INPUT/OUTPUT ... 409

8.1 FILE

INPUT/OUTPUT UNITS ... 409

8.1.1 Memory Card (only on R-30iB) ...412

8.1.2 USB Memory ...414

8.2 SETTING A COMMUNICATION PORT... 419

8.3 FILES... 423

8.3.1 Program File ...423

8.3.2 Default Logic File ...424

8.3.3 System File/Application File...424

8.3.4 Data File ...424

8.3.5 ASCII File ...424

8.4 SAVING

FILES ... 424

8.4.1 Saving with Program Selection Screen ...425

8.4.2 Saving all the Program Files Using the File Screen ...426

8.4.3 Saving with a Function Menu ...432

8.4.4 File Manipulation ...434

8.4.5 ASCII save ...440

8.5 LOADING

FILES... 441

8.5.1 Loading Using the Program Selection Screen...442

8.5.2 Loading a Specified Program File Using the File Screen ...443

8.6 PRINTING

FILES... 449

8.7 SUBDIRECTORIES... 452

8.8 AUTOMATIC

BACKUP ... 455

8.8.1 Overview of Automatic Backup ...455

8.8.2 Usable Memory Cards...455

8.8.3 Setting of Automatic Backup ...455

8.8.4 Perform Automatic Backup ...457

8.8.5 Version Management...458

8.8.6 Restore the Backup...459

8.9 IMAGE

BACKUP FUNCTION ... 460

8.10 ASCII PROGRAM LOADER FUNCTION... 465

8.10.1 Overview ...465

8.10.2 Loading an ASCII Teach Pendant Program from the Teach Pendant ...466

8.10.3 Viewing ASCII Program Loading Errors...467

8.10.4 Example ASCII File ...468

8.11 FILE

MEMORY ... 470

9 UTILITY ... 471

9.1 MACRO

INSTRUCTION ... 471

9.1.1 Setting Macro Instructions ...472

9.1.2 Executing Macro Instructions ...478

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9.2.1 Program Shift Function ...483

9.2.2 Mirror Shift Function ...489

9.2.3 Angle Entry Shift Function ...492

9.3 COORDINATE SYSTEM CHANGE SHIFT FUNCTIONS... 497

9.4 POSITION REGISTER LOOK-AHEAD EXECUTION FUNCTION... 501

9.5 TIME

BEFORE FUNCTION ... 503

9.6 DISTANCE

BEFORE FUNCTION ... 508

9.6.1 Overview ...508

9.6.2 Specification ...508

9.6.3 Configuration ...509

9.6.4 Instruction...509

9.6.5 Entering Distance before ...516

9.6.6 Caution and Limitations ...520

9.7 POINT

LOGIC

INSTRUCTION ... 521

9.8 CONDITON

MONITOR FUNCTION ... 525

9.9 COLLISION

DETECTION

FOR AUXILIARY AXIS... 533

9.9.1 General ...533

9.9.2 Caution ...533

9.9.3 Initial Setting ...533

9.9.4 Tuning Procedure ...533

9.10 PASSWORD

FUNCTION ... 535

9.10.1 Overview of the Password Function...535

9.10.2 Password Operations by the Install User...536

9.10.3 Disabling the Password Function ...540

9.10.4 Password Operations by Program Users and Setup Users ...544

9.10.5 Password Configuration File ...550

9.10.5.1 Overview ... 550

9.10.6 XML Syntax for Password Configuration Files ...551

9.10.6.1 Software parts ID, Screen ID... 551

9.10.6.2 Basic tag ... 553

9.10.6.3 Comment tag... 554

9.10.6.4 Level name tag... 554

9.10.6.5 Local Labels tag... 554

9.10.6.6 Screen Access tag ... 555

9.10.6.7 Features tag... 556

9.10.6.8 Default menu type tag... 556

9.10.6.9 Default screen tag ... 556

9.10.6.10 FCTN/display menu access tag... 557

9.10.6.11 EDCMD access tag... 558

9.10.7 Password Log ...558

9.10.8 Screen Restrictions According to Password Level...560

9.10.9 Password Auto Login Function ...561

9.10.10 USB Password Function...562

9.11 BACKGROUND

LOGIC ... 564

9.11.1 Execution Modes and Scan Time ...564

9.11.2 Available Instructions for Background Logic ...565

9.11.3 Execution and Setting of Background Logic...567

9.11.4 Other Instructions and Functions ...568

9.11.5 Backup for Background Logic ...573

9.12 ORIGINAL

PATH RESUME... 573

9.12.1 Original Path Resume...573

9.12.2 Resume Offset ...577

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B-83284EN/04

9.14 ERROR

SEVERITY TABLE... 586

9.14.1 Error Severity Table Overview ...586

9.14.2 Modifying Error Severity ...586

9.15 DIAGNOSTIC LOG... 590

9.15.1 Overview ...590

9.15.2 Operations ...590

9.15.3 Getting Out the Save Data...591

9.15.4 Output to External Device ...592

9.15.5 Delete the Data Saved in FROM ...592

9.15.6 Limitation ...593

9.16 ROBOT TOOLS OF ROBOT HOMEPAGE ... 593

9.16.1 Setup for ROBOT TOOLS...594

9.16.1.1 Setup IP Address ... 594

9.16.1.2 Setup HTTP AUTHENTICATION ... 597

9.16.2 Usage of ROBOT TOOLS ...598

9.17 GROUP

MASK

EXCHANGE ... 603

9.18 CIRCLE ARC MOTION INSTRUCTION ... 606

9.18.1 Way of Teaching ...607

9.18.2 Normal Motion ...607

9.18.3 Direction of the Circular Motion...609

9.18.4 Cases Circular Path Cannot be Planned ...609

9.18.4.1 Shortage of the circle arc motion instruction... 609

9.18.4.2 Teaching of same position ... 610

9.18.4.3 The case the three points are in line... 611

9.18.4.4 The case circular arc bigger than 180 deg ... 611

9.18.5 Resume After Pause ...612

9.18.5.1 Resume after JOG... 612

9.18.6 Resume After Pause and Modification of Programs ...613

9.18.6.1 Change of destination point ... 613

9.18.6.2 Change of next destination point ... 613

9.18.6.3 Deletion of next circle arc motion instruction and resume ... 613

9.18.6.4 Current instruction becomes the first circle arc motion after modification ... 615

9.18.7 Pause and Resume from Another Circle Arc Motion Instruction...617

9.18.8 Start of Program from the Circle Arc Motion ...618

9.18.9 Single Step Execution ...618

9.18.10 Backward Execution...618

9.18.11 Backward Execution after Abort ...619

9.18.12 Backward Resume from Different Line ...619

9.18.13 Logic Instructions between the Circle Arc Motion ...619

9.18.14 Available Motion Options ...621

9.18.15 Change of Position Data during Execution of the Circle Arc Motion Instruction622 9.18.16 Restrictions...623

9.19 iRCALIBRATION VISION MASTER RECOVERY ... 623

9.19.1 Overview of Vision Master Recovery ...623

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9.19.3 System Configuration for Executing Vision Master Recovery ...624

9.20 OVERVIEW

OF KAREL... 624

9.20.1 What is KAREL?...624 9.20.2 Feature ...625 9.20.3 Setup before Use of KAREL...625 9.20.4 How to Load KAREL Program...625 9.20.5 How to Run KAREL Program ...626

9.20.5.1 Running KAREL program using SELECT screen ... 626 9.20.5.2 CALL KAREL program by TP program ... 627 9.20.5.3 Register as MACRO program... 628 9.20.5.4 Message display by KAREL program ... 628

9.20.6 KAREL Variable and KAREL Position Variable ...629

10 PALLETIZING

FUNCTION... 631

10.1 PALLETIZING FUNCTION ... 631

10.2 PALLETIZING

INSTRUCTIONS ... 633

10.3 TEACHING THE PALLETIZING FUNCTION... 635

10.3.1 Selecting a Palletizing Instruction ...635 10.3.2 Inputting Initial Data ...637 10.3.3 Teaching a Stacking Pattern ...644 10.3.4 Setting Path Pattern Conditions...650 10.3.5 Teaching a Path Pattern ...653 10.3.6 Notes on Teaching the Palletizing Function...656

10.4 EXECUTING THE PALLETIZING FUNCTION ... 657

10.4.1 Palletizing Register...658 10.4.2 Controlling the Palletizing Function by a Palletizing Register ...659

10.5 MODIFYING THE PALLETIZING FUNCTION ... 660

10.6 PALLETIZING

FUNCTION

WITH EXTENDED AXES ... 662

10.7 PALLETIZING

ALL-POINT TEACHING ... 663

11 APPLICATION

FUNCTION OF TEACH PENDANT ... 665

11.1 SCREEN

DISPLAY FUNCTIONS... 665

11.1.1 Internet Browser Screen ...665 11.1.2 Status Sub-window...667

11.1.2.1 Current position display... 668 11.1.2.2 Operator panel status display... 668 11.1.2.3 Stop signal status display... 669

11.1.3 Wide Screen Mode ...669 11.1.4 Screen Maximization...670 11.1.5 Zoom ...670

11.2 OPERATION

FUNCTIONS... 672

11.2.1 Cursor Positioning by Touch Panel...672

11.3 PROGRAM

EDIT FUNCTIONS ... 673

11.3.1 ICON Editor ...673

11.4 CUSTOMIZATION FUNCTIONS ... 676

11.4.1 Overview ...676 11.4.2 Background Color ...676 11.4.3 Setting up the HMI Screen ...677 11.4.4 Menu Favorites...680 11.4.5 Top Menu Setup ...681 11.4.6 User Views ...684 11.4.7 Setting up iPendant Touch Panel...686 11.4.8 History ...688

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B-83284EN/04

11.5 OPERATION PANEL... 688

11.5.1 Overview ...688 11.5.2 Basic Operation ...689 11.5.3 Panel Setup ...691

11.5.3.1 Operation panel setting screen... 691 11.5.3.2 Item select screen... 693 11.5.3.3 Item setting ... 693 11.5.3.4 Panel enable condition setting ... 695 11.5.3.5 Finish setting... 696 11.5.3.6 Save and restore setting value... 696 11.5.3.7 Register panel ... 697

11.5.4 Restriction ...699

APPENDIX

A SCREEN/PROGRAM INSTRUCTIONS ... 703

A.1 LIST

OF MENUS ... 703

A.2 LIST OF PROGRAM INSTRUCTIONS... 708

A.3 PROGRAM

INSTRUCTIONS ... 713

A.3.1 Motion Instructions ...713 A.3.2 Additional Motion Instructions ...713 A.3.3 Register and I/O Instructions...715 A.3.4 String Register, String Instructions ...717 A.3.5 Mixed Logic Instructions ...718 A.3.6 FOR/ENDFOR Instructions ...719 A.3.7 Conditional Branch Instructions...719 A.3.8 Wait Instruction ...720 A.3.9 Unconditional Branch Instructions...720 A.3.10 Program Control Instructions ...721 A.3.11 Other Instructions ...721 A.3.12 Skip and Offset Condition Instruction...722 A.3.13 Frame Setup Instruction ...723 A.3.14 Macro Instruction ...724 A.3.15 Multiaxis Control Instructions...724 A.3.16 Position Register Look-ahead Execution Instruction ...724 A.3.17 Status Monitoring Instructions ...724 A.3.18 Motion Group Instructions ...725 A.3.19 Diagnose Instruction...725 A.3.20 Palletizing Instructions (Software Option:J500) ...726

B SPECIAL

OPERATION ... 727

B.1 START

MODE ... 727

B.1.1 Start Up Methods...727 B.1.2 Initial Start...728 B.1.3 Controlled Start ...729 B.1.4 Cold Start...730 B.1.5 Hot Start ...732

B.2 MASTERING ... 732

B.2.1 Jig Mastering ...734 B.2.2 Mastering at the Zero-degree Positions ...736 B.2.3 Quick Mastering ...738 B.2.4 Single Axis Mastering ...741 B.2.5 Setting Mastering Data ...744

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B.4 ROBOT

AXIS

STATUS... 748

B.5 DIAGNOSIS

SCREEN ... 752

B.5.1 Outline ...752 B.5.2 About Reducer Diagnosis...753 B.5.3 Procedure...753 B.5.4 Each Item...753

B.6 WORLD

FRAME ORIGIN ... 755

B.7 I/O

MODULE

SETTING ... 756

B.8 FSSB

LINE SETUP ... 759

B.8.1 Definition of FSSB Line...759 B.8.2 Setting 1 (FSSB line)...760 B.8.3 Setting 2 (Number of total axes on FSSB line 1) ...761 B.8.4 Setting 3 (Hardware start axis) ...761 B.8.5 Setup Examples ...762

B.8.5.1 Example 1 ... 762 B.8.5.2 Example 2 ... 763 B.8.5.3 Example 3 ... 763

B.9 POSITIONER SETUP... 764

B.10 EXTENDED

AXIS SETUP ... 774

B.11 INDEPENDENT

ADDITIONAL AXIS SETUP... 783

C SYSTEM

VARIABLES ... 791

C.1 FORMAT OF A SYSTEM VARIABLE TABLE... 791

C.2 SYSTEM

VARIABLES ... 793

D SAVING

RESEARCH DATA ... 807

D.1 DIAGNOSTIC LOG... 809

D.2 MAINTENANCE DATA ... 811

D.3 All

BACKUP ... 812

D.4 IMAGE

BACKUP ... 814

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B-83284EN/04

1. INTRODUCTION

1 INTRODUCTION

This chapter explains the manual plan.

Contents of this chapter

1.1 MANUAL PLAN

About this manual

FANUC Robot series (R-30iB/R-30iB Mate CONTROLLER) OPERATOR’S MANUAL.

This manual describes how to operate the FANUC Robot, an all-purpose compact robot. It is controlled by the FANUC R-30iB and R-30iB Mate controller (called the robot controller hereinafter) containing the FANUC Robot software.

This manual describes the following items for manipulating workpieces with the robot: • Setting the system for manipulating workpieces

• Operating the robot

• Creating and changing a program • Executing a program

• Status indications

• Backup and restore robot programs.

Using this manual

Each chapter of the manual describes a single operation of the robot. The user can select and read chapters describing required operations.

Chapter 1

Introduction Describes how to use this manual. Chapter 2

Overview

Gives a basic knowledge of the robot. It describes the basic configuration of the robot and the system for Robot.

Chapter 3

Setting the System for Robot

Describes the procedure for setting the system for Robot including input/output, coordinate system, and reference position.

Chapter 4

Program Structure Describes the program structure and the syntax of program instructions. Chapter 5

Creating a Program

Describes how to design, create, change, delete, and copy a program. It also describes the procedures for turning the power on and moving the robot by jog feed. Chapter 6

Executing a Program

Describes how to execute and stop a program. It also describes the test operation, automatic operation, and recovery from the alarm state.

Chapter 7 Status Indications

Describes how to check the operating status of the robot, using the status indicator LEDs.

Chapter 8

File Input/Output Describes how to store, read, and print a program file or system file. Chapter 9

Utility

Describes additional utility functions, macro functions, program shift and mirror shift, and so on.

Chapter 10

Palletizing Function Describes the setting and executing of palletizing function. Chapter 11

Application function of teach pendant

Describes the setting and operation for the application function of the teach pendant.

Appendix Describes lists of the menus, screens, program instructions and detail of program, special operations, lists of the system variables, saving research data.

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Identification

For editions of software, read the following sections:

Item to be checked Section

Edition of your software B.3 SOFTWARE VERSION

Specifications of products

For memory statuses, see the following sections:

Item to be checked Section

Memory status 7.12 MEMORY USE STATUS DISPLAY

Related manuals

The following manuals are available:

OPERATOR’S MANUAL (Basic Operation) B-83284EN (This manual)

Intended readers:

Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site.

Topics:

Functions, operations and the procedure for operating the robot. Programming procedure, interface and alarm.

Use:

Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

OPERATOR'S MANUAL (Alarm code list) B-83284EN-1

Topics:

Error code listings, causes, and remedies. Use:

Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot. Optional Function

OPERATOR’S MANUAL B-83284EN-2

Intended readers:

Topics:

Description of the software optional functions. Use:

Arc Welding Function OPERATOR’S MANUAL B-83284EN-3

Intended readers:

Topics:

Description of the setting and operation for arc welding application software.

Use:

Robot controller

Spot Welding Function OPERATOR’S MANUAL B-83284EN-4

Intended readers:

Topics:

Description of the setting and operation for spot welding application software.

Use:

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B-83284EN/04

1. INTRODUCTION

Dispense Function

OPERATOR’S MANUAL B-83284EN-5

Intended readers:

Topics:

Description of the setting and operation for dispense application software.

Use:

Robot controller

MAINTENANCE MANUAL B-83195EN (for R-30iB), B-83525EN (for R-30iB Mate)

Topics:

Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot.

Mechanical unit OPERATOR’S MANUAL Topics:

Installing and activating the robot, connecting the mechanical unit to the controller, maintaining the robot.

Use:

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2 OVERVIEW

This chapter shows the basic configuration of the FANUC Robot System and briefly describes the functions of each component.

Contents of this chapter

2.1 APPLICATION TOOL SOFTWARE 2.2 ROBOT

2.3 CONTROLLER

A FANUC robot system consists of the tool software for manipulating workpieces, the mechanical unit of the robot itself (FANUC Robot series), and the Robot controller.

The FANUC robot offers outstanding performance when handling or welding.

Tool software for application

The tool software for application is a software package for all kinds of Robot’s manipulations installed on the Robot controller. Any work can be performed by specifying menus and instructions from the teach pendant. The tool software for manipulating workpieces contains instructions for controlling the robot, hands, remote controllers, and other peripheral devices.

The I/O between an additional axis or controller and another peripheral device can be controlled. Other peripheral devices include cell controllers or sensors.

Robot

Robot has a hand or another end effector interface for control to do work. The FANUC robot is ideal for manipulating workpieces.

Controller

The Robot controller supplies power to drive the mechanical unit.

The tool software for manipulating workpieces is installed on the Robot controller to control the teach pendant, operator’s panel, and external peripheral devices.

Peripheral devices, including remote controllers, are required to configure a system for manipulating workpieces.

• The remote controllers are used to control the Robot controller.

• The hands, sensors, and other devices are operated using I/O and serial communication units.

Fig. 2 shows a typical robot system for manipulating workpieces. The system consists of a robot, the Robot controller, and peripheral devices.

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B-83284EN/04

2. OVERVIEW

2.1 APPLICATION TOOL SOFTWARE

The Application tool software has been specially designed to perform manipulating workpieces operations. The Application tool software is contained in the Robot and enables the following:

• Setting up the system for Robot applications • Creating a program

• Performing the test operation of a program • Performing the automatic operation • Status display or monitoring

When optional functions are incorporated, the system can be expanded and the management functions can be enhanced.

2.1.1 System Setting

The Application tool software has an interface for specifying parameters of operation of the manipulation system. (For how to set the Robot system, see Chapter 3.)

With the Application tool software, the hands, the remote controller, and other external units can be controlled. Before the manipulation is started, the following must be specified: input from and output to the hand and other peripheral units, the coordinate system, communication, and automatic operation.

2.1.2 Jog Feed of the Robot

Jog feed of the robot is the operation of moving the robot as desired by manually entering commands on the teach pendant. In order to teach a motion instruction in a program, the robot is moved to the target position by jog feed, then the position is recorded. (For the jog feed of the robot, see Subsection 5.2.3.)

2.1.3 Program

A program contains motion instructions, input/output instructions, register instructions, and branch instructions. (For the program structure, see Chapter 4.) Each instruction is assigned a statement number. The target work is accomplished by sequentially executing the instructions.

The teach pendant is used to create or correct a program. (For creation of a program, see Chapter 5.) The program contains the following instructions. Fig.2.1.3 shows a basic program for manipulating workpieces.

• Motion instruction: Moves the tool to the target position within the operating range.

• Additional motion instruction: Performs an additional (special) operation during a motion.

• Register instruction: Places (loads) numerical data into a register.

• Position register instruction: Places (loads) position data into a register.

• Input/output instruction: Sends or receives a signal to or from a peripheral unit.

• Branch instruction: Changes the flow of a program.

• Wait instruction: Holds execution of the program until the specified conditions are satisfied.

• Routine call instruction: Calls and executes a subprogram.

• Macro instruction: Calls a specified program and executes it.

• Palletizing instruction: Palletizes workpieces.

• Program end instruction: Terminates execution of a program.

• Comment instruction: Adds a comment to a program.

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SAMPLE1 1/9 1: J P[1] 100% FINE 2: HAND1CLOSE 3: J P[2] 70% CNT50 4: L P[3] 500mm/sec CNT10 5: HAND1OPEN 6: L P[4] 500mm/sec CNT10 7: HAND1CLOSE 8: END [End] > POINT TOUCHUP Program name Line number Macro instruction Motion instruction End instruction Program end symbol Program instructions

Fig. 2.1.3 Robot program

2.1.4 Test Operation (Test Execution)

After the system is set and a program is created, perform the test operation in the test execution mode to check the program for normal operation. (For the test operation, see Section 6.3.)

The test execution of the program is one of the important steps in creating a good program. Before starting automatic operation, perform the test execution of the created program.

2.1.5 Automatic Operation (Operation Execution)

Automatic operation (operation execution) is the final step in executing programs. In automatic operation, the following processing is executed:

• Specified programs are started one after another. (For automatic operation, see Sections 3.8 and 6.6.) • During automatic operation, position data can be corrected (online position correction Section 6.7). • The processing is halted, then aborted or resumed. (For halting a program, see Section 6.1.)

2.2 ROBOT

A robot is a mechanical unit consisting of axes and arms driven by servo motors. A place at which arms are connected is a joint, or an axis.

J1, J2, and J3 are main axes. The basic configuration of the robot depends on whether each main axis functions as a linear axis or rotation axis.

The wrist axes are used to move an end effecter (tool) mounted on the wrist flange. The wrist itself can be rotated about one wrist axis and the end effector rotated about the other wrist axis.

J1 ＋ - ＋ -J2 -＋ J3 ＋ -J4 ＋ -J5 J6 ＋

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-B-83284EN/04

2. OVERVIEW

Fig. 2.2 (b) Hand with fingers

Fig. 2.2 (c) Hand with suction cups and no fingers

2.3 CONTROLLER

Robot controller includes a power unit, user interface circuit, motion controlling circuit, memory circuit, h pendant and operator's box to operate the controller.

bot axes, including any ain CPU circuit interfaces the controller with the peripheral units by receiving and sending and input/output circuit.

The user should use a teac

The operation control circuit controls the servo amplifier which moves all the ro additional axes, via the main CPU printed circuit board.

The memory circuit can store programs and data set by the user in the C-MOS RAM on the m printed circuit board.

The input/output (I/O)

signals via the I/O link cable and peripheral connecting cable. The remote input/output signal is used for communication with the remote controller.

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Robot controller

Operator panel Three mode switch

Teach pendant

Fig. 2.3(a) Robot controller R-30iB

Teach pendant (iPendant)

Operator panel

Breaker Teach pendant hook

(option)

USB port (option)

Fig. 2.3 (b) Robot controller R-30iB Mate

The circuitry of the controller depends on the robot and the system it controls. For details, refer to the “FANUC Robot series R-30iB CONTROLLER MAINTENANCE MANUAL” (B-83195EN) or “FANUC Robot series R-30iB Mate CONTROLLER MAINTENANCE MANUAL” (B-83525EN).