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AMO-NP-03017-34

Maintenance Tool for the SC3000 Robot Systems

3000SPWin Operation Manual (For Maintenance Work Users)

3000SPWin Operation Manual for Maintenance Work Users

AMO-NP-03017-34

SC3000 Robot Systems 3000SPWin Operation Manual For Maintenance Work Users This English version manual has been prepared according to the descriptions of the latest issue of the corresponding Japanese version (7th issue dated March 1, 2005) listed below:

7th issue dated March 1, 2005

Notices for Safety

This notice advises of a condition that could present a potential hazard where serious personal injury or loss of life is possible unless care is used.

This notice advises of a condition that could present a potential hazard where personal injury or damage of material are possible unless care is exercised and correct operations are performed

March 2005 Edition Sankyo Seiki Mfg. Co., Ltd. Ina Plant 6100 Uenohara, Ina-shi Nagano-Pref., Japan (Postal Code 396-8511) TEL 0265 (78) 5111 FAX 0265 (78) 5116 Copyright © 2002, Sankyo Seiki Mfg. Co., Ltd.

CAUTION

□ No part of this manual may be used or reproduced in any manner whatsoever without the written permission of Sankyo Seiki Mfg. Co., Ltd.

□ All descriptions included in this manual are subject to change without notice.

□ This publication may contain technical inaccuracies or typographical errors. Any of your questions and comments on the contents of this document should be directed to Sankyo Seiki Mfg. Co., Ltd.

□ Sankyo Seiki Mfg. Co., Ltd. is exempt from any responsibilities, for damages caused directly and/or indirectly by the contents of this manual.

DANGER !


AMO-NP-03017-34

Contents

● Related Documents

● For Safety Work

1. Generals .......................................................................................................................................1 2. Operation Environment .................................................................................................................1 3. Installing and Uninstalling of 3000SPWin......................................................................................3

3.1 Installing...................................................................................................................................3 3.2 Uninstalling ..............................................................................................................................4

4. Basic Operations...........................................................................................................................5 4.1 Online Operation......................................................................................................................5 4.2 Offline Operation......................................................................................................................5 4.3 Main Screen.............................................................................................................................6 4.4 Setup of 3000SPWin................................................................................................................8 4.5 User levels ...............................................................................................................................9

4.5.1 How to Control the User Levels ......................................................................................9 4.5.2 How to Change the User level ...................................................................................... 10

5. Various Maintenance Functions .................................................................................................. 11 5.1 Controller status monitor ........................................................................................................ 11

5.1.1 Controller error.............................................................................................................. 11 5.1.2 Task status monitor....................................................................................................... 12 5.1.3 DI/DO monitor ............................................................................................................... 15 5.1.4 Robot current position monitor ...................................................................................... 16 5.1.5 Version check ............................................................................................................... 17

5.2 Maintenance work.................................................................................................................. 18 5.2.1 Change operation range ...............................................................................................18 5.2.2 Motor replacement ........................................................................................................ 19 5.2.3 Change home position .................................................................................................. 23

5.3 Servo monitoring.................................................................................................................... 24 5.3.1 Buffering ....................................................................................................................... 24 5.3.2 Monitor the thermal value and implementation value.................................................... 27

5.4 ROM communication ............................................................................................................. 29 5.4.1 Outline of ROM communication .................................................................................... 29 5.4.2 Erase all in flash ........................................................................................................... 29 5.4.3 Upload Controller System Software .............................................................................. 29 5.4.4 Download System Software to Flash ............................................................................ 29

5.5 Axis move .............................................................................................................................. 30 5.6 File manager .......................................................................................................................... 31 5.7 HWDEF editor........................................................................................................................ 33


AMO-NP-03017-34

Notices for Robot System Users This manual has been prepared on the premise, for safety reasons, that the personnel who read and use this manual have already acquired sufficient knowledge on operation of automated equipment and devices.

Before any operation or maintenance work begins on the robot system(s), be sure to read and understand the section titled, “For Safety Work”, which soon appears in this manual.


AMO-NP-03017-34

Related Documents For the robot system(s), there are various instruction manuals listed below and you are requested to refer to those documents as you require. Listed below are the documents related only to the SC3100 robot systems.

System Instructions Rev. 3 provides the comprehensive information on the SC3150/SC3400 Robot Systems.

Installation Manual Rev. 3 describes how to install the Controller, the way of cabling work, how to perform the ABS homing, etc.

SC3150 Controller Hardware Manual SC3400 Controller Hardware Manual

describes electrical specifications on the corresponding Controller. Instructions on AD1309 Expansion I/O Card (Option) Instructions on AD1319 Expansion I/O Card (Option) Instructions on AD1339 HS Card (Option)

describes electrical specifications and other information on each expansion card. Instructions on AD1316 Safety Connector (Option)

describes electrical specifications and other information on the AD1316 Safty Connector.

Instructions on AD1340 Remote Switch Box describes electrical specifications and other information on the AD1340 Remote Switch Box.

Instructions on AB4301 CC-Link Card (Option) describes electrical specifications and other information on the AB4301CC-Link Card.

Buzz2 User’s Guide describes the operation of Buzz2, which has been developed as “ADS” (*).

Pendant Operation Manual (Option) Rev. 3 describes the operation of the Pendant to be used, being connected to the Controller.

3000SPWin Operation Manual (For General Users) describes the operation of the maintenance work software, 3000SPWin, for the SC3000 series robot systems.

3000SPWin Operation Manual (For Maintenance Work Users) This manual.

SC3150 Controller Maintenance Manual SC3400 Controller Maintenance Manual

describes the checks and parts replacement work, spare parts, etc. for the corresponding Controller.

SSL/E Language Reference Manual Rev. 2 SSL/E means “Sankyo Structured Language / Enhanced”, a robot language to be used for the SC3000 Series Robot Systems. Discussed in this manual are; how to create programs in SSL/E, syntax of SSL/E and detailed information on each language command.

Manipulator Hardware Manual describes the installation, maintenance and inspection work for the Manipulator. Specifications depending on the Manipulator are given in this manual.

(*) “ADS” stands for the Application Development System and it is the name of the software development environment, which is used to create Robot programs in SSL/E on a PC and download them to the Controller to enable testing of source program level.


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For Safety Work

1. Introduction

Industrial robots usually have wide workspace and their manipulators move in high speed. Since they require special working procedures, such as teaching operation, any industrial robots is accompanied by some critical operating condition that other industrial systems do not have. Furthermore, erroneous motion may potentially be caused in the robot systems by wrong operation or electromagnetic noise effect. The Sankyo SC3000 Robot Systems are supplied with various safety operation functions, and descriptions on safety operations are included in the manuals and their related publications. All the Sankyo Robot users are highly recommended to read the entire “For Safety Operation” publication and the other related manuals to become familiar with safety operations and instructions for the SC3000 Robot Systems.

1.1 General Notice Ensure compliance with all local, state and national safety and electrical codes for the installation and operation of the Sankyo Robot System. For example, if you used the Sankyo robot in the USA, you need to be very familiar with the American National Standards Institute / Robotic Industries Association (ANSI/RIA) safety standard R15.06-1992. In other countries, the equivalent codes and/or standards shall be observed.

1.2 Training Course In the codes and standards regarding industrial robots, it is described that the operators who perform teaching, inspection and tuning, and repair work for industrial robots are obligated to receive special training for their work. All the operators for such work of the Sankyo Robot Systems and their safety administrators need to receive instruction through the special training course organized by Sankyo.

1.3 Scheme for Safety Operation Administration For using the Sankyo Robot Systems, you shall designate the persons in charge of the Robot operation and its safety operation respectively. Furthermore, organize the scheme for safety operation administration, such as emergent norm and reporting network, in preparation for emergencies.

1.4 Working Norm For safety operation administration, prepare the working norm and ensure to observe the norm.


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2. Precautions for Installation and Operations

2.1 Installing a Safety Barrier Consider installing a safety barrier to avoid any person from stepping into the Manipulator workspace.

① It must be possible to see the Manipulator movement through the barrier from its outside.

② The barrier shall have enough rigidity with which the barrier would neither easily get moved, broken nor damaged.

③ The barrier shall have an entrance only through which the operator can enter the barrier inside.

④ A safety plug shall be placed at the entrance, which the operator pulls out before entering the Manipulator workspace to disable the Manipulator from moving.

2.2 Installation Environment

If your installation site is relevant to any of the following items, consider improving the installation environment or taking countermeasures required.

① The temperature at the installation site is out of the range of 0～40℃. ② The humidity at the installation site is out of the range of 30～90% RH, or the

temperature changes so quickly that moisture condensing is caused. ③ Some noise generator(s), (such as high-voltage equipment, electric driving

systems, etc.) is located near to the installation site. ④ Oil mist and/or dust is generated at or around the installation site. ⑤ Corrosive gas is generated at or around the installation site. ⑥ The installation site is in explosive or inflammable atmosphere. ⑦ Excessive vibration and/or mechanical shock is generated at or around the

installation site. ⑧ The installation site is ill-ventilated because of bad ventilation condition.

2.3 Installation

When installing the robot system, pay attention to the following notes:

① In order to perform teaching operation and maintenance/inspection work safely, provide the robot system and its peripheral equipment with sufficient working area for the operator.

② The robot system and its peripheral equipment shall be so installed as that the operator can always see them. Wire emergency stop button(s) from more than 1 of I/O-1, I/O-2 or AUX connector of the Controller to make operator(s) push the emergency stop button easily and stop the Manipulator.

③ The Pendant shall be so placed that the operator can use it outside the Manipulator workspace while watching the Manipulator movement.

④ Refer to the “Installation Manual” as well for the other notices regarding installation work.


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2.4 Connecting Cables

- If you perform soldering work for the primary power cable plug with

the primary power cable being connected to the switchboard, you would potentially have electric shock. Be quite sure not to perform soldering work under such condition.

- The primary power connector (POWER) and Manip. Power connector (C1) (also the C2, C3 connectors in any case of 6-axis models of the SC3150 and the SC3400) include some high voltage sections that may cause electric shock. Before you connect or disconnect any of those related cables; be sure to turn off the Controller power switch and breaker switch, then follow the procedure to prevent someone from turning the power ON accidentally (the Lock-out / the Tag-out).

- Disconnecting any robot interface cable, while the Manipulator is in operation, may cause overrun. Fasten the connectors with screws for sure.

- Connect only the Controller and Manipulator that have the identical C.CODE. Should any Controller and Manipulator having different C.CODEs be connected, the Manipulator may cause overrun.

2.5 Connecting Peripheral Equipment

- Before connecting any peripheral equipment, check the rated

voltage and current of the equipment. Connecting peripheral equipment having its rated voltage and/or current outside the specified allowable range may cause the Controller to get damaged.

- Do not keep the “/STBY” input always being turned on. Keeping it always turned on, a realtime error occurs. Be sure to use pulse input switching for the "/STBY" input.

2.6 Releasing Brakes

- When you release a brake by pulling its brake release ring, the

section of the robot hand and chuck would unsafely drop down. On this occasion, keep your body away from the space under the robot hand and chuck.

DANGER !

DANGER !

CAUTION


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3. Preparation of Working Norm Referring to the descriptions below and the manuals on the SC3000 Robot Systems, make up your working norm and ensure to observe it. For the communication to the observing personnel and the operator(s) of the other related equipment, prepare the safety care sheets and perform communication according to the descriptions on them. On such an occasion, oral communication may have some problem because of noisy working locations and using body language may be recommended.

3.1 Checks Before Robot Operations Before placing the SC3000 Series Robot System into operation, perform the following checks. If you find any problem, repair the broken part or take actions required for the problem. You are recommended to make your own checklist, referring to the following descriptions:

① Check on the safety plug Check that removing the safety plug of the safety barrier entrance surely causes an emergency stop.

② Check on the cables

- The primary power connector (POWER) and Manip. Power

connector (C1) (also the C2, C3 connectors in any case of 6-axis models of the SC3150 and the SC3400) include some high voltage sections that may cause electric shock. Before you connect or disconnect any of those related cables; be sure to turn off the Controller power switch and breaker switch, then follow the procedure to prevent someone from turning the power ON accidentally (the Lock-out / the Tag-out).

a. Make sure that the interface cables are free from any damage on their

outer cover. b. Make sure that the EMS cable is free from any damage on its outer cover. c. Check that there exists no damage such as a dent with the Controller,

Pendant and/or Manipulator outside section.

③ Check on the Manipulator movement After making sure of no person inside the Manipulator workspace, try to move every axis by using the Pendant to check if the Manipulator moves smoothly without any unusual noise.

④ Check on the emergency stop button function Check that pressing each of the emergency stop buttons (of the Pendant and the external emergency stop button if any) surely stops operation.

⑤ Making sure of no obstacle Make sure that there exists no obstacle inside the Manipulator workspace.

DANGER !


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3.2 Precautions for Teaching Operation

① Whenever possible, teaching operation shall be done while the operators being outside the Manipulator workspace. If it is impossible to perform teaching operation in that way, extreme attention shall be paid in preparation for unpredictable erroneous motion and operation because the Manipulator moves at high speed.

② All personnel for teaching operation including observing personnel shall have received special instruction for their work, and only the personnel appointed by the responsible chief person can perform teaching operation.

③ Be sure to wear safety helmets, safety shoes and safety glasses. ④ For teaching work, two men are required. One does teaching operation while the

other is observing the teaching at the control panel. ⑤ The observing personnel is to do the following:

a. Devote himself to observing while standing at the position where all the robot motion can be seen.

b. Press the emergency stop button immediately in an emergency. c. Make no body other than the teaching personnel penetrate the work area.

⑥ The personnel carrying out teaching operation shall always be ready to press the emergency stop button.

⑦ Before teaching work, perform pre-work checking with the check list which you make according to item “3.1 Checks Before Robot Operations” of this manual. In case any unusual condition is found, take an appropriate action to solve the problem.

⑧ The Manipulator speed in teaching shall be 250 mm/sec or less. ⑨ Place a "NOW TEACHING" sign plate onto the control panel. ⑩ If you must enter the safety barrier inside section, pull out the safety plug at the

entrance of the barrier and carry it with you. ⑪ For the communication to the observing personnel and the operator(s) of the other

related equipment, the descriptions of the safety care sheets shall be observed. ⑫ Neither operate nor allow to operate any equipment, which may act as a noise

generator, at the teaching operation area or its surrounding area. ⑬ Do not use the Teaching Pendant by groping it while paying attention to only the

teaching points. ⑭ Do not perform your work while turning your back to the Manipulator. ⑮ Before teaching work, make sure that there is no obstacle near your feet. Be

careful to perform teaching work while standing on any high step (2 m or higher). ⑯ When a failure comes up during your teaching operation, take actions as described

below: a. Press the Emergency Stop button immediately when any erroneous

motion is observed. b. Communicate with the observing personnel to turn off the main power

and place a "DO NOT TURN ON" sign plate at the main power switch. c. When you check the failure after causing an emergency stop, first make

sure that the other related equipment is also stopping. d. Pull out the safety plug at the entrance of the barrier and carry it with

you during your work. e. If the robot automatically stops due to power failure, ensure to stop the

robot, then check the problem cause to take actions required. f. If any emergency stop device does not work, immediately turn off the

main power, then check the problem cause to take actions required. g. Only the appointed personnel can do the work of problem solving.


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⑰ To boot up the robot again after causing an emergency stop because of some

problem, first make the problem cause(s) clear and take the actions required. Then carry out the re-booting operation according to the procedures described in item “3.3 Operation Procedures“.

3.3 Operation Procedures

① Powering up a. Turn on the main power

(a) Make sure that the switch you are now going to turn on is the main power switch of the control panel.

(b) Make sure that nobody is in the Manipulator workspace. (c) Make sure that no sign plate of "DO NOT TURN ON" is placed at the

main power switch. (d) After making sure of the points described above, turn on the main power

switch of the control panel. (e) At the time, check that the manipulator does not move at all.

b. Turn on the servo power (a) According to what operation you want to do, turn the mode of the

Controller (*1) to the “Local” or “Teach”. (b) Turn the Key Switch of the Pendant to the same position as the mode of

the Controller is turned to. (c) Press the Manip. Power Switch (servo power switch = Green button) of

the Pendant. (d) Make sure that the Servo power LED (Manip. Power) gets lighted. (e) If the Manipulator shows any motion (even slightly) at this time, press the

Emergency Stop button to turn off the servo power. (f) If any error happens in the procedures up to here, consult your

maintenance team to ask for taking actions.

Note *1: The mode of the Controller The mode of the Controller means the mode setup of the Controller side. It is different between the Controller models.

<In the case of the SC3150 & SC3400> The mode setting input has prepared at the AUX connector in the rear section of the Controller. It is set by equipment that users wired or the mode change switch of the Remote Switch Box, AD1340 (Option).

<In the case of the SC3100 & SC3300> It is set by the mode change switch in front of the Controller.

<In the case of the SC3000 & SC3200> The mode change switch of the Controller do not exist, therefore only the mode change switch of the Pendant decide the operation mode.


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② Initial operation check

Perform initial operation check, usually at the beginning of the robot operation, to make sure that not only the robot system but also the other related equipment work properly.

a. Selecting the operation mode.

Turn the Key Switch of the Pendant and the mode of the Controller to the “Local”.

b. Verifying the robot motion by the "Step" operation

(a) Press the “Step” key on the Pendant LCD screen. (b) Make sure that there is neither unusual motion nor any teaching point

displacement.

c. Verifying the robot motion by continuous operation (a) Press the "Start" key on the Pendant LCD screen to perform the

continuous operation from the top of the program. On this occasion, by using the “Speed Override” function, first perform the continuous operation at low speed, and then at the specified speed if there exists no problem.

(b) Make sure that there is neither unusual motion nor any teaching point displacement.

(c) In this operation, you shall always be ready to press the Emergency Stop button.

③ Teaching operation

a. Selecting the “Teach” mode Turn the Key Switch of the Pendant and the mode of the Controller to the “Teach”.

b. Using the Pendant, operate each axis to perform teaching and save the

teaching data. The following precautions shall be observed through the teaching operation. (a) Make sure that nobody is in the Manipulator workspace. (b) Avoid any sudden motion of the Manipulator. (c) Operate the Manipulator as slow as possible. (d) Make sure that there is no obstacle near your feet. (e) Do not deal with the Pendant roughly. (f) Always be ready to press the Emergency Stop button. (g) While holding the Pendant with your left hand, operate it with your right

hand. ④ Debugging

Debug the program created by using Buzz. On this occasion, with the “Speed Override” function, first perform the operation at low speed, and then at the specified speed if there exists no problem.


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3.4 Check Work Procedures

① As a general rule, check work should be done while the robot is out of operation. If you must perform check work while the robot is in operation, you shall do it, keeping your body outside the Manipulator workspace. If you perform check work inside the Manipulator workspace while the robot is out of operation, ensure to turn off the main power switch of the control panel and place a "DO NOT TURN ON" sign plate onto the control panel.

② Check work shall be done only by the personnel who has received special instruction for their work and has been appointed by the responsible chief person.

③ Even if having received special instruction for their work, the personnel shall not perform any check work for other equipment for which the personnel is not responsible.

④ Be sure to wear safety helmets, safety shoes and safety glasses. ⑤ To perform check work, contact with the responsible chief person to get permission

for it. Then, after obtaining the permission, perform the work with observing the precautions described below:

a. For check work, two men are required. One of the two shall work as observing personnel.

b. The observing personnel is to do the following: (a) Devote himself (herself) to observing while standing at the position where

all the robot motion can be seen. (b) Press the emergency stop button immediately in an emergency. (c) Make no body other than the teaching personnel penetrate the work

area. c. Place a "NOW CHECKING" sign plate onto the control panel. d. For the communication to the observing personnel and the operator(s) of the

other related equipment, the descriptions of the safety care sheets shall be observed.

e. Enough attention shall be paid in preparation for unpredictable erroneous motion and operation because the Manipulator moves at high speed.

f. Do not perform check work while turning your back to the Manipulator. g. During check work, the observing personnel shall keep the Emergency

Stop button in his hands to get ready for pressing it anytime. h. Neither operate nor allow to operate any equipment, which may act as a

noise generator, at the check work area or its surrounding area. i. When an error condition comes up during check work, take actions as

described below: (a) Press the Emergency Stop button immediately when any erroneous

motion is observed. (b) Communicate with the observing personnel to turn off the main power

and place a "DO NOT TURN ON" sign plate at the main power switch. (c) When you check the failure after causing an emergency stop, first make

sure that the other related equipment is also in stop condition. (d) Pull out the safety plug at the entrance of the barrier and carry it with you

during your work. (e) If the robot automatically stops due to power failure, ensure to stop the

robot, and then check the problem cause to take actions required. (f) If any emergency stop device does not work, immediately turn off the

main power, and then check the problem cause to take actions required. (g) Only the appointed personnel can do the work of problem solving. (h) To boot up the robot again after causing an emergency stop because of

some problem, first make the problem cause(s) clear and take the actions required. Then re-install the safety plug and boot up the robot again by operation from the safety barrier outside.


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⑥ If a failure comes up during the robot operation and you need to perform check work

to make the problem cause(s) clear, pay attention to the points described below: a. When the failure comes up, make sure of the operating condition of the

system by checking the operation indicator lamps. b. Determine if you can take actions while the system being out of operation. c. Regarding the failure classification, way to determine failures and way of

problem solving; refer to the problem solving procedures (which will be prepared separately for each system according to its particular specifications).

⑦ After all check work and making sure of nobody inside the Manipulator workspace, remove the “NOW CHECKING” sign plate from the control panel. Then inform the personnel in charge of the system operation of the completion of your work.


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4. Notices on the Manipulator and Controller

4.1 C.Code Label Shown below are the detailed caution notices regarding the C.CODEs on the C.CODE labels, which you would find on the Manipulator and Controller. Ensure to observe these caution notices:

Connect only the Controller and Manipulator that have the identical C.CODE. Should any Controller and Manipulator that have different C.CODEs be connected, the Manipulator may cause overrun.

4.2 “Hazardous Voltage” Label Shown below are the detailed caution notices regarding hazardous voltage label (See above), which you would find on the Controller. Ensure to observe these caution notices:

- The primary power connector (POWER), Manip. Power connector

(C1) (also the C2 connector in any case of 6-axis models of the SC3150, and the C2, C3 connector of the SC3400) include some high voltage sections that may cause electric shock. Before you connect or disconnect any cable of these connectors, ensure to turn off the Controller power switch and turn off the main breaker switch, then follow the procedure to prevent someone from turning the power ON accidentally (the Lock-out / the Tag-out).

- After removing the Controller top cover, make sure that the hazardous voltage indicator LED on the servo amplifier (Yellow) or the mother board (Amber) is surely off.

DANGER!

DANGER !


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4.3 “No Entry” Warning Label

Shown below are the detailed notices regarding the “No Entry” warning labels (See above) which you would find on the Manipulator or safety barrier. Ensure to observe these caution notices:

- While the robot is in operation, do not penetrate the Manipulator workspace.

- Whenever possible, carry out teaching operation while the operators being outside the Manipulator workspace. If you must penetrate the Manipulator workspace, be sure not to penetrate under the Robot or between the Robot and the wall, always be ready to press the Emergency Stop button in preparation for unpredictable erroneous motion and operation.

- As a general rule, check work should be done while the robot is out of operation. If you must perform check work while the robot is in operation, you shall do it, keeping your body outside the Manipulator workspace.

DANGER !


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5. Other Precautions

5.1 Ban on Reconstruction of Robot Without consulting Sankyo, you shall not reconstruct any of the Manipulator, Controller, Pendant, etc.

5.2 Translocation, Grant or Re-sale of Robot If you translocate, grant or re-sell the robot, you shall attach the operation manuals to the system and explain that the new owner also needs to read and understand them. The robot operators of the new owner shall receive instruction for their work through the special training course organized by Sankyo.

5.3 Discarding Robot When being discarded, the robot shall be dealt with as an industrial scrapped material. You shall observe the following precautions to discard the robot: ① Used-up Ni-Cd batteries are to be recycled. When discarding the robot, you are

expected to return the used-up Ni-Cd battery to the battery manufacturer while paying your attention to the following points:

1) Way of dealing with Ni-Cd batteries Insulate the connector(s) of the used-up battery(s) with insulation tape and then package up the battery(s). (Do not take apart any Ni-Cd battery. Return used-up batteries collectively if possible.) Do not try to put any used-up Ni-Cd battery into fire, and/or to heat up or take part it. Trying to do so may result in explosion of the battery or make the electrolyte scatter to cause some critical condition.

2) Destination

SANYO GS Soft Energy Co., Ltd. Environmental Control Section, 1-FL Office, Central #2 Bld. Ichinodan-cho 5, Kichijohin Shinden, Minami-ku, Kyoto City Post Code 601-8397, Japan TEL: 075-311-1292

3) The freight charge for returning the used-up battery(s) shall be paid by the user.

② Electrolytic condensers are to be discarded as industrial waste, without being disassembled.


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5.4 Remarks for Systematization

The system integrator for the Sankyo robot shall make the operation manual(s) for the systematized total robot system by themselves. The manual(s) shall describe the following contents at least: ① Clearly describe how to operate the system and the system movements. ② Noticeably give descriptions about possibly dangerous operations to call attention. ③ Noticeably give descriptions about the cases where system damages may be caused

and/or critical condition may come up. ④ When the system is modified, accordingly revise the operation manual(s) at once. ⑤ If the system integrator performs systematization in cooperation with the system user,

clearly describe the scope of responsibility of each party. ⑥ Describe the safety notices about the main operation service of the robot.


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1. Generals

Being prepared for maintenance work users as the operation manual on 3000SPWin, i.e., Maintenance Software for the SC3000 Controller, this document describes the way of using the various functions of 3000SPWin. Therefore, the objective readers of this document are supposed to have trained through the special training course organized by Sankyo and have enough knowledge on the maintenance work. Operating on a Windows software platform, this software application provides the SC3000 Controller with the maintenance functions for the Controller through the serial communication from a personal computer (hereinafter, called the PC).

2. Operation Environment To operate this program application, you need to have the operation environment described below:

① OS (Operating System) Microsoft Windows 95, Windows 98, Windows ME, Windows NT, Windows 2000 or Windows XP

• Microsoft Windows 95, Windows 98, Windows ME, Windows NT, Windows 2000, or Windows XP are registered trademarks of Microsoft Corporation in the USA and other countries.

② Display

Minimum requirements: Desktop area: Resolution of 800 X 600 pixels Font size: Small fonts (Font size 100%)

Recommended specifications:

Desktop area: Resolution of 1024 X 768 pixels Font size: Small fonts (Font size 100%) Color palette: 65536 color

• If you use any fonts larger than the size specified above, characters on the

screen may become incomplete or the screen itself cannot possibly be displayed in full size.

• Depending on the language you use for the screen indication, the minimum requirement mentioned above may not realize the correct screen indication. If you have such a problem, apply the recommended specifications described above.

③ Communication port

RS-232C


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④ PC

To enable the operation of the OS described above, and be equipped with one or more communication port(s) mentioned above.

⑤ Language used in the screen Depends on the OS to be used. Japanese OS : Japanese Other language’s OS : English

Note: In Windows NT, it is possible to change the setting for language in Control Panel →Regional Settings. However, using any other OS (Windows 9X systems or Windows 2000), you may have problems in the screen indication if the language of the OS is different from the language specified in Control Panel →Regional Settings.

⑥ Types of Controllers

Depending on the version of the Controller you use, there are some restrictions on the items of the functions. If the version of your Controller is Version 2.30 or earlier, you are possibly not able to use some of the functions that carry out file transmission.


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3. Installing and Uninstalling of 3000SPWin

3.1 Installing

1. When installing the 3000SPWin software, insert the Buzz2 CD into the CD drive of your

PC to execute the Setup.exe of 3000SpWin\installer folder. Then follow the instructions given by the installer program.

2. Just after you have installed the 3000SPWin software, the user level is initially defined to be as “User” and only the functions for general users are available. To make it possible to utilize the various maintenance work functions, you need to change the user level to “Maintenance”. For details of how to control and change the user level, refer to 4.5 User Levels of this manual.

3. To enable you to change the user level to “Maintenance”, you need to execute the user level controller (LevelController_Mente.exe) to set your password. The user level controller exists in 3000SPWin\LevelController folder. Enter your password into the password box (① in the following figure) as you need. The password shall be specified with 1-255 alphanumeric characters. Upper case and lower case characters are discriminated each other. Since you need to use the password in your future work, keep it in your memory or make a note of it for sure.


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4. After setting the password, press the Enable the “Maintenance” level button (② in the

figure on the previous page) to make the Maintenance level enabled. 5. Exit the user level controller, and then boot up 3000SPWin. 6. Select the 3000SPWin configuration button in the main screen to have the 3000SPWin

configuration screen come up. 7. At the section of the User level in the 3000SPWin configuration screen, select the

Maintenance button. Subsequently you are prompted to enter the password. Then enter the password that you defined in the user level controller. In case you cannot select the Maintenance eventually, return to item 3. above and re-define the password by using the user level controller. Regarding the 3000SPWin configuration screen, refer to 4.4 Setup of 3000SPWin in this manual.

8. Once you have selected the Maintenance at the section of the User level, you can successfully complete the user level setting work.

3.2 Uninstalling When uninstalling the 3000SPWin software, use the function of Add/Remove Programs from Control Panel. 1. Execute Control Panel → Add/Remove Programs. 2. Select 3000SPWin from the list of programs to delete it. 3. The uninstaller gets booted to delete 3000SPWin and you are to follow the instructions

that appear on the screen. 4. Uninstalling completes.

Note: Whenever you update 3000SPWin with its newer version, be sure to uninstall the existing 3000SPWin software at first and then install the new one.


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4. Basic Operations

4.1 Online Operation

a) When the objective Controller is the SC3000:

1. Connect the PC to the SC3000 Controller with a communication cable.

2. Boot up 3000SPWin.

3. In the 3000SPWin configuration screen, set the Baud rate (bps) to be 9600.

4. In the main screen, execute the Read controller information command by pressing the corresponding button to read the key information on the Controller.

5. Execute various functions, as you require.

b) When the objective Controller is the SC3100/SC3150/SC3300/SC3400:

1. Connect the PC to the SC3100 Controller with a communication cable.

2. Boot up 3000SPWin.

3. In the 3000SPWin configuration screen, set the conditions for communication. At this step, check the baud rate by using the Pendant if you carry out communication through RS232C. Then set the communication speed as you checked.

4. In the main screen, execute the Read controller information command by pressing the corresponding button to read the key information on the Controller.


When you change the connection of the communication cable to another Controller while keeping on 3000SPWin operation, you must carry out step 3. above again. In the online operation, this application operates on the basis of the information acquired by executing the Read controller information command. If there exists any conflict between the information that the application has at the time and the actual information of the Controller, the functions of this application software do not work properly.

4.2 Offline Operation 1. Boot up 3000SPWin.

2. In the 3000SPWin configuration screen, specify the Axis number (= No. of axes) and HS (= The number of the HS cards to be used).


In the offline operation, this application operates on the basis of the information specified in the 3000SPWin configuration screen.


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4.3 Main Screen

The main screen of 3000SPWin for the User level: Maintenance appears as shown below: The main screen of 3000SPWin supports the functions described below:

① Configuration status Indicates the information on the configuration status of the Controller that 3000SPWin has at the time.

② Get operation mode / Cancel operation mode Gets or cancels the operation mode.

③ Read controller information Loads the information on the Controller to which the PC of 3000SPWin is connected.

④ 3000SPWin configuration Brings the screen of 3000SPWin configuration. Regarding setup of 3000SPWin, refer to 4.4 Setup of 3000SPWin.


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⑤ Controller status monitor

Monitors various kinds of the Controller condition. Regarding the Controller status monitor, refer to 5.1 Controller status monitor.

⑥ Maintenance work Enables you to carry out Change Operation Range, Motor Replacement, and Change Home Position. Regarding the Maintenance work, refer to 5.2 Maintenance work.

⑦ Servo monitoring Enables you to monitor various data of the servo operation. Regarding the Servo monitoring, refer to 5.3 Servo monitoring.

⑧ ROM communication Enables you to carry out ROM communication. Regarding the ROM communication, refer to 5.4 ROM communication.

⑨ Axis move Enables you to cause Axis move of each robot axis. Regarding the Each axis action, refer to 5.5 Axis move.

⑩ File manager Enables you to carry out operation on the file(s) existing in the flash-memory drive of the Controller. Regarding the File management, refer to 5.6 File manager.

⑪ Hwdef editor Boots up HWDEF editor. Regarding the functions of HWDEF editor, refer to 5.7 HWDEF Editor.

⑫ Version info. Gives you information on the version of the 3000SPWin.

⑬ Exit Causes you to exit 3000SPWin.

Note: If you operate 3000SPWin on Windows 95, 98 or ME and change the screen display to have a new message box, sometimes your objective message box may not appear on top of the monitor screen so that you cannot enter from the keyboard. In such a case, press the Alt key to make the message box appear on top.


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4.4 Setup of 3000SPWin

The setup screen of 3000SPWin, i.e., “3000SPWin configuration”, appears as shown below. In the screen of “3000SPWin configuration”, you can set the following items:

① Various setup data The setup condition specified in this screen is saved when the application quits. Then the robot system starts operation on the basis of the setup when it gets booted up.

• HS Defines the no. of HS cards in the Controller. Usually you are to define in offline condition. If you use 3000SPWin in online condition, it is defined automatically with the Read controller information command.

• No. of axes Defines the no. of axes of the Controller. Usually you are to define in offline condition. If you use 3000SPWin in online condition, it is defined automatically with the Read controller information command.


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• Target controller

Defines the objective Controller. Usually you are to define in offline condition. If you use 3000SPWin in online condition, it is defined automatically with the Read controller information command.

• Communication port Defines the communication port of the PC.

• Baud rate (bps) Defines the baud rate of the serial port of the PC. When the objective Controller is an SC3000 Controller, only 9600bps is applicable. When the objective Controller is an SC3100 Controller, you can choose a baud rate, as you require, from the multiple selections. It is possible to identify the baud rate setup of the Controller at the time with the Pendant. The default baud rate of the SC3100 Controller is 115,200bps.

• ArcNet Node ID Defines the Node ID of the communication object when ArcNet communication is used.

• User level Defines the user level for using 3000SPWin. There are three user levels, i.e., User / Maintenance / Sankyo only, and there are some restrictions on using the functions depending on each user level. For details of the User level, refer to 4.5 User Levels in this manual.

② Return to “Main menu”

Pressing this key exits the screen of “3000SPWin configuration” to return to the main menu.

4.5 User levels 3000SPWin enables you to change various setting conditions of the robot. There are three user levels to place restrictions on using the functions to change those setting conditions. The three user levels are User / Maintenance / Sankyo only, and there are some restrictions on using the functions depending on each user level. The Sankyo only has the highest degree of freedom to use the functions, and it is followed next by the Maintenance. Then the User comes last.

4.5.1 How to Control the User Levels The user levels are controlled in double steps. The first step is to define whether the objective user level is enabled or not. To define it, use the user level controller (LevelController_Mente.exe) to set your password for changing the user level and press the Enable the “Maintenance” level button. Then the User level: Maintenance in 3000SPWin becomes enabled. To the contrary, pressing the Disable the “Maintenance” level button makes the User level: Maintenance in 3000SPWin disabled. Note that the User level: User is always enabled.


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The second step is to change (shift) the user level as required in the screen of “3000SPWin configuration”. In this setting step, you can change (shift) to either user level as far as it is enabled. When changing to the higher user level (with the higher degree of freedom to use the maintenance functions), you need the password that you have set in the first step by using the user level controller.

Caution Setting the higher user level (i.e., Maintenance) makes it possible to change some critical setting conditions of the robot system. On the other hand, it may bring you a chance to cause some serious accidents, depending on the setting contents. Therefore, the “User level: Maintenance“ shall be used only by those people who have correct knowledge and understand the correct operation method. Consequently it is recommended to make the Maintenance for the user level disabled as soon as you have completed the setting work that requires the Maintenance. Furthermore, the user level controller shall be administered by the person having knowledge on the maintenance work, and it is recommended to usually protect the function of the user level controller by using a password unless needed.

4.5.2 How to Change the User level Changing to the higher user level is different from changing to the lower user level. a. Changing to the lower level (Maintenance → User)

If you want to change to the lower user level, simply make a change at the User level section in the screen of “3000SPWin configuration” and exit the setting.

b. Changing to the higher level (User → Maintenance)

If you want to change to the higher user level;

1. Use the user level controller to set your password for changing to the objective user level, and enable the user level.

2. In the screen of “3000SPWin configuration”, make a change at the User level section.

3. Enter the password you have defined in advance.

4. If once the User level setting gets changed, you can successfully quit the user level changing work.


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5. Various Maintenance Functions

The information on maintenance work includes various data on the Controller. When any axis is indicated and/or designated regarding the data on the motion axes, it is generally named with logic axis naming to avoid any confusion of the logic axes (in the axis order in SSL/E language) and physical axes. Then the axes are expressed with blue characters in the monitor screen.

5.1 Controller status monitor Using the Controller status monitor, you can monitor the data of the Controller described in this section.

5.1.1 Controller error This function enables you to view the historical error data of the Controller that is connected at the time. The screen of “Controller error” is as shown below. Note that the data are indicated in due order of the physical axes: ① Config. interpretation error

(Detailed error code) : Refer to Chapter 4. Errors of the System Instructions

regarding the detailed error codes.

② Error record number : Indicates the error record number.

③ Save data with ASCII style : Saves the contents of the error record data into text format (.CSV format).

①

③

②


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5.1.2 Task status monitor This function enables you to view the condition of each task of the Controller that is connected at the time. ① System task SI/SL monitor : Monitors each condition of the system task. Any item,

which the objective Controller does not support, indicated with “-“ or, it is not indicated at all.

② Task selection : Selects the task to be monitored at item ③. Any item, which the objective Controller does not support, indicated with “-“ or, it is not indicated at all.

③ Task SI/SL monitor : Monitors the task specified by item ②.

④ ArcNet status : Monitors the ArcNet status.


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Supplement: Details of Object status, Command process status, and Interpreter

status Codes of Object status:

Code Condition 0 Initial condition 1 Normal condition -1 No objective file in the RAM disc -2 Object checksum error of the RAM disc -3 No objective file in the file system -4 Object checksum error in the file system -5 Teaching data: File end found halfway. -6 Teaching data: In the object program, there is no data having the same name as

loaded from the file. -7 Teaching data: Conflict on the number of data between the file and object -8 Teaching data: The specified file does not exist. -9 Teaching data: TPOSITION with its data undefined -10 Teaching data: Error detected by the file driver -11 Teaching data: Conflict on the number of axes between the teaching data and the

system -20 Teaching data: Other undefined error -21 The area for local variable(s) cannot be secured. -22 Conflict on the number of axes between the object and the system

Codes of Command process status:

Bit Code Condition 0 0x00000001 System error 1 0x00000002 Real time error 2 0x00000004 ABS error 3 0x00000008 Configuration error 4 0x00000010 Robot undefined 5 0x00000020 “JOBDEF.CFG” undefined 6 0x00000040 The object program does not exist. 7 0x00000080 (Reserve) 8 0x00000100 Program error of the task itself 9 0x00000200 The task itself is in operation.

10 0x00000400 The task itself is not in operation 11 0x00000800 (Reserve) 12 0x00001000 Servo OFF 13 0x00002000 Non-executable mode 14 0x00004000 Robot task program error 15 0x00008000 System task program error 16 0x00010000 Overrun / External emergency stop 17 0x00020000 Interpreter pointer in initial condition - - - - - - - - - - - - 31 0x80000000 Normally completed


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Codes of Interpreter status:

Codes Condition 0 Initial condition 1 In operation 2 To execute stop 3 Break point 4 Cycle stop 5 Step stop 6 Hold stop 7 Program error 8 Real time error 9 Emergency stop


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5.1.3 DI/DO monitor

This function enables you to monitor the DI/DO status of the Controller, which is connected at the time, and to turn ON/OFF the selected output port compulsorily. The screen of “DI/DO monitor” is as shown below: ① This section shows the DI/DO status of each port.

② This key compulsorily turns on the selected port. The function is effective only for an output port. To execute this function, you need to get the operation mode in the main screen.

③ By using these keys, you need to select the port that you want to turn ON/OFF compulsorily.

④ This key compulsorily turns off the selected port. The function is effective only for an output port. To execute this function, you need to get the operation mode in the main screen.

⑤ Scroll up and down the page of the status indication.

⑥ By using these keys, select the DI/DO you want to monitor.


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5.1.4 Robot current position monitor

This function enables you to monitor the current position of each robot with various data. It is also possible by logic pulse correction to make the logic pulse at the time of correction “0”. The screen of “Robot current position monitor” is as shown below: ① At this item, select the robot whose current position you want to monitor.

② This section shows the current position of the selected robot.

③ Using these keys enables to make a correction of the logic pulse. In the logic pulse correction, the monitor values of the logic pulses are modified so that the logic pulse at the time of correction becomes “0”. In this procedure, only the indication values are modified and the Controller setting values are actually not changed.


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5.1.5 Version check

This function shows the information on the system software version of the Controller being connected at the time, as well as the information on the version of the booting ROM. ① Information on the version: To show the information on the system software version of

the Controller being connected at the time


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5.2 Maintenance work

The Maintenance work includes the contents described below:

5.2.1 Change operation range This operation provides the functions required for changing the operation range (Manipulator’s workspace). The functions are described as follows:

5.2.1.1 HWDEF Setting This function sets the data on the workspace in the HWDEF.CFG file. When changing the workspace data, you can edit the maximum and minimum values on the workspace as well as the initial offset values. The screen of “HWDEF setting” is as shown below: ① On the tab page, the HWDEF data of each robot are indicated.

② You can monitor the set values of the HWDEF data. The items, which you can edit, vary depending on the menu.

③ After your setting work, press the OK button. Then the updated HWDEF.CFG file is downloaded into the flash-memory drive of the Controller. To make the edited contents effective, you need to once turn off the Controller and then turn it on again after downloading the HWDEF.CFG file.

④ Pressing the Cancel button quits the editing work without saving the changed data.

⑤ Use this button when you want to save the data set at the time into a file on the PC.

5.2.1.2 Robot current position monitor

This function enables you to monitor the current positions of robots. For details, refer to 5.1.4 Robot current position monitor in this manual.


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5.2.2 Motor replacement

This operation provides the functions required for motor replacement work. The functions are described as follows:

5.2.2.1 HWDEF Setting This function sets the data on the motor replacement in the HWDEF.CFG file. In relation to the motor replacement, you can edit the values of the Pole offset, Offset for calibration and Shifting coordinate. For details, refer to 5.2.1.1 HWDEF Setting on the previous page.

5.2.2.2 Return to initial home position (Initial homing) “Return to Initial Home Position” shall be put into practice only once after motor replacement to define the home position of the motor. “Return to Initial Home Position” can be carried out only in online condition. If you carry out “Return to Initial Home Position”, the home position may be changed so that you need to check the data values of the teaching positions, being currently used, which are related to the corresponding axis.

Procedures

The procedures of “Return to Initial Home Position” homing are as described below: 1. Upload the HWDEF.CFG file from the Controller.

2. Select the axis (axes), for which you carry out “Return to Initial Home Position” (Only for the axis/axes that actually needs the initial homing).


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Place a check mark into the check box of each axis, for which you want to carry out “Return to Initial Home Position”. Pressing the Cancel button quits the procedures of “Return to Initial Home Position” instantly. In such a case, the problem of “Initial home position lost condition” and/or “ABS home lost” condition” is not solved.

3. Carry out the homing operation procedures by following the instructions that appear on

the monitor screen.

4. Download the HWDEF.CFG file into the Controller.

5. Once turn off the Controller and then turn it on again.

Putting the above procedures into practice, you can complete the procedures of “Return to Initial Home Position”.

5.2.2.3 TH2 axis calibration (for SCARAs) This function is used to carry out the TH2 (θ2) axis calibration for SCARA type robots, and eventually it is used only for SCARA type robots. For the calibration work, follow the instructions that appear on the monitor screen. The outline of the workflow is as described below: 1. Upload the HWDEF.CFG file.

2. Move to the reference point with the right-elbow posture.

3. Set a dial gauge at the reference point.

4. Obtain the current position pulse data.

5. Then, move to the reference point with the left-elbow posture.

6. Make a fine adjustment until the dial gauge indicates the value set in step 3.above.

7. Obtain the current position pulse data.

8. Implement the calibration work.

9. Set the offset data, which you have obtained through the calibration, into the HWDEF.CFG file.

10. Download the HWDEF.CFG file.

11. Re-boot up the Controller.

5.2.2.4 Robot current position monitor

This function enables you to monitor the current positions of robots. For details, refer to 5.1.4 Robot current position monitor in this manual.


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5.2.2.5 Shifting coordinate value calculation

This function calculates the shifting coordinate values by making use of the teaching data existing. When the entire Manipulator is displaced or the relation between the positions of the Manipulator and objective workpiece changes entirely, this function still enables to use the existing program (teaching data) by shifting the coordinate system of the Manipulator. This function can be used both in online condition and offline condition. 1. If the application, i.e., 3000SPWin, is operated in online condition, the HWDEF.cfg file

of the Controller is uploaded at first. On the other hand, if it is operated in offline condition, you are supposed to select a HWDEF.cfg file existing in the PC.

2. In the case of any multiple robots, select an objective robot (① in the above figure).

3. Enter the teaching data values of the two teaching points (② in the above figure).

4. Next, enter the current data of the positions corresponding to the objective two points (③ in the above figure).

5. Click on the OK button after entering all the data required (④ in the above figure). Subsequently the calculation results are indicated.

6. If you want to cancel the calculation, click on the Cancel button (⑤ in the above figure).


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7. Pressing the OK button in the dialog makes the existing values overwritten with the

calculation results. In online condition or offline condition, the data are reflected on the data in the Controller or the file you have selected at first, respectively.

Note: Even though the shifting coordinate values have already been once overwritten

according to the calculation, executing this command again still re-overwrites the existing values. When the coordinate values are overwritten two or more times in that way, it becomes unsure if the overwritten coordinate values are accurate enough. In such a case, it is recommended to newly create teaching data again.


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5.2.3 Change home position

This operation provides the functions required for changing the home position. The functions are described as follows:

5.2.3.1 HWDEF Setting This function sets the data on the home position changing in the HWDEF.CFG file. In relation to the home position changing, you can edit Homing direction and speed, the maximum and minimum values on the workspace, Initial offset, and Offset for calibration. For details, refer to 5.2.1.1 HWDEF Setting on the previous page.

5.2.3.2 Return to initial home position (Initial homing) This function carries out “Return to Initial Home Position”. For details, refer to 5.2.2.2 Return to initial home position (Initial homing).

5.2.3.3 TH2 axis calibration (for SCARAs) This function is used to carry out the TH2 (θ2) axis calibration for SCARA type robots. For details, refer to 5.2.2.3 TH2 axis calibration (for SCARAs).

5.2.3.4 Robot current position monitor This function enables you to monitor the current positions of robots. For details, refer to 5.1.4 TH2 Robot current position monitor.


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5.3 Servo monitoring

The Servo monitoring includes the contents described below:

5.3.1 Buffering By this operation, you can monitor various servo data. It enables you to set the buffering process, to read buffered data and to display wave curve data. The read data can be saved into a file. Any file saved in the original format can be displayed later too, and eventually this function can also make it possible to display those file data even in offline condition. The screen of “Buffering” is as shown below:

① Select buffering axis

[Physical axis] : Sets the axis (axes) for which data buffering is done.

Each axis number is specified as a physical axis. Each corresponding logic axis is described with blue characters at the right side of the axis number in the form of “Axis number (Robot number)”.


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② Select buffering item : Select the data item for which data buffering is done.

③ Setting of the buffering interval

: Sets the buffering interval.

④ Buffering start : Sets the setup contents defined by items ①, ② and ③ mentioned above. At that time, the buffering memory of the Controller gets cleared.

⑤ Axis move : Implements the robot axis motion. The axis (axes) for buffering set by item ① is described with physical axis number, but for the Axis move, logic axis numbers are used. Before executing the function, make sure whether the specified axis number is correct or not.

For details of the Axis move, refer to 5.5 Axis move in this manual.

⑥ Data read : Causes reading the buffered data. Then the read data are displayed in the graph shown on the right-hand side.

⑦ Save data : Saves the read data in the original format.

⑧ File data display / End of file data display

: Selecting the File data display loads the file saved in the original format in step ⑦, and displays it. If you want to read the buffered data of the Controller in online condition, select the End of file data display.

⑨ Save data with the ASCII style

: Saves the data read by the Data read and/or those loaded by the File data display, in text file format (.CSV format).

⑩ Graph : Displays the data read by the Data read and/or those loaded by the File data display, in the graph.

⑪ Select display axis [Physical axis]

: Selects the axis (axes) whose data are to be displayed in the graph. Each axis number is specified with logic axis naming.

⑫ Select display data : Selects the data to be displayed in the graph.

⑬ Size of grid : Specifies the graduation (grid) size in the graph.

⑭ Detail of selected data : Indicates the detailed data values of the data selected at the time. The data at the point, where each colored dotted line is crossing, are those selected at the time. The data can be selected by right-clicking on the objective graph.

⑮ Origin value of time axis : Specifies the value at the start point on the time axis.


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<Buffering method> 1. Specify the buffering condition by items ①, ② and ③, and then press the Buffering start

button (④ in the figure).

2. By using the Axis move or others, operate the axis (axes) specified by item 1. above.

3. By pressing the Data read button (⑥ in the figure), read the buffered data.

4. Then the read data are displayed in the Graph section.


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5.3.2 Monitor the thermal value and implementation value

By this operation, you can monitor and sample the Thermal values, Implementation values (execution values) and Implementation counters. ① Selects the robot that you want to monitor and/or sample.

② Indicates of the values of the robot specified by item ①.

③ Sets the sampling interval for monitoring.

④ Sets the sampling condition, which is specified by the Interval & time or Interval & number. The file, into which the sampled data are saved (to be saved in .CSV format), is also specified at this section.

⑤ Starts monitoring. To quit monitoring, select the End of monitor/ sampling of item ⑦.

⑥ Starts sampling. To quit sampling, select the End of monitor/ sampling of item ⑦.


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⑦ Quits sampling and monitoring.

⑧ Resets the implementation (execution) values.

⑨ Shows the status of the sampling operation.


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5.4 ROM communication

The ROM communication is a function that enables you to communicate with the booting ROM in order to save the system software into the flash-memories and RAMs of the Controller and Pendant

5.4.1 Outline of ROM communication To enable the ROM communication, it is necessary that the Controller and Pendant are

operating in the ROM communication mode. While being in the ROM communication mode, the Controller has its error LED on the front panel being lighted.

The ROM communication supports the following condition on the communication:

• RS-232C communication port • Baud rate 9600bps

5.4.2 Erase all in flash

This function erases all the files existing in the flash-memory drive of the Controller.

5.4.3 Upload Controller System Software This function uploads the system file out of the flash-memory drive of the Controller.

5.4.4 Download System Software to Flash This function downloads the system file into the flash-memory drive of the Controller. In case the downloading does not successfully complete, once execute the Erase all in flash function to delete the files existing in the flash-memory drive of the Controller and then try the Download System Software to Flash function again.


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5.5 Axis move

The Axis move (= Each axis action) enables each robot axis to cause its motion. To use this function, the robot servo needs to be turned on. ① Selects the robot, which you want to move, and sets various motion parameters.

② Sets the Joint coordinate (Axis coordinate) position of each axis. If you place a check mark into the check box positioned on the right next to the coordinate box, the corresponding axis does not move.

③ Causes the robot to move as specified by items ① and ②. For the robot motion, it is needed to get the operation mode (④ in the figure) and to servo on the objective axis (axes).

④ Gets or release the operation mode accordingly.


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5.6 File manager

The File manager is a function to be used to indicate the directory status of the flash-memory drive of the Controller and to upload, download and/or delete files to/from each drive.

1. Indicating the directory status:

This function indicates the directory status of the flash-memory drive (⑧ in the figure). The file names, file size (bytes) and date & time information are indicated in the section. If you press the Refresh directory button (⑨ in the figure) to update the list indication, the list shows you the latest directory status information.

2. File uploading:

A file is uploaded from the drive. For such uploading, specify the name of the file to be uploaded (④ in the figure), a file name, with which the file is saved in the PC (③ in the figure), and its file type (② in the figure). Then press the File upload button (⑥ in the figure).


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3. File downloading:

A file is downloaded into the drive. For such downloading, specify the name of the file to be downloaded (the file name in the PC, with its full path: ③ in the figure), a file name, with which the file is saved in the Controller (④ in the figure), and its file type (② in the figure). Then press the File download button (⑤ in the figure). A file name in the Controller must be composed of 8 or less alphanumeric characters, and no Japanese character can be used for the name.

4. File deleting:

A file is deleted from the drive. Pressing the Delete button (⑦ in the figure) deletes the file selected by the Controller File Name (④ in the figure) out of the Controller. If once you delete any file from the Controller, you cannot undo the deletion and the file cannot be restored anymore. Before deleting any file, carefully make sure if your file deletion is really adequate.


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5.7 HWDEF editor

Generals

• The HWDEF editor is used to edit the contents of the HWDEF.cfg file, which is a configuration file of the SC3000 Robot controller.

• The items to be edited are classified into the groups of Controller and Robot*_Pendant. The contents of Robot*_Pendant can be set for each robot.

• The HWDEF editor can be used in both the online and offline conditions. If it is used in online condition, the HWDEF.cfg file of the objective Controller connected at the time is automatically uploaded. On the other hand, if it is used in offline condition, you can designate an objective file existing in the PC.

Screen of HWDEF editor

The screen of HWDEF editor appears as shown on the next page:

① Editing section Enables you to edit the contents of the HWDEF.cfg file. When you boot up the HWDEF editor, initially the Controller tab page is indicated to show the setup condition at the time. The Pendant tab and Robot*_Pendant and Robot* tab page can be set.

① ② ③ ④


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② OK

Saves the edited contents of the tab page(s) and quits the HWDEF editor. If the application, i.e., 3000SPWin, is operated in online condition, the edited HWDEF.cfg file is downloaded into the Controller. To make the edited contents effective at the time, you need to once turn off the Controller and then turn it on again. On the other hand, if it is operated in offline condition, the edited contents are saved into the file being opened at the time.

③ Cancel Quits the HWDEF editor without saving the edited contents.

④ Save to PC Enables you to save the edited contents at the time into the PC.

Editing the HWDEF.cfg file

The procedures of editing the HWDEF.cfg file by using the HWDEF editor are as described below:

1. Booting up the HWDEF editor • Boot up the HWDEF editor in the main screen of 3000SPWin. At this time, the

HWDEF.cfg file is automatically uploaded from the Controller.

• If the uploading fails, a dialog appears to ask you if you want to boot up the editor application in offline condition. Then, selecting “Yes” boots up the editor.

• When you boot up the editor application in offline condition, open a HWDEF.cfg file existing in the PC that you want to edit. The name of the file you open does not necessarily need to be “HWDEF.cfg”.

• The window title section shows the editor operating mode at the time, i.e., “Online” or “Offline”.

2. Editing the file contents

Edit the contents of the file you open.

3. Quitting the HWDEF editor • After editing the contents of the file, press the OK button.

• If the application, i.e., 3000SPWin, is operated in online condition, pressing the OK button downloads the edited HWDEF.cfg into the Controller. To make the edited contents effective at the time, you need to once turn off the Controller and then turn it on again.

• On the other hand, if it is operated in offline condition, the edited contents are saved into the file being opened at the time.


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Details of the items to be edited

1. On the Controller page

High speed ‘MDOSET’

Description : Define the setup if you want to specify the time interval to be faster for the DO control command (MDOSET command) in the SSL/E that synchronizes with the robot motion.

Setting Not used : Possible

Version of the applicable Controller

: Version 1.40 or later

Applicable values : High speed (2.4 m-sec) / Standard (10 m-sec)


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Option of error output

Description : Define the setup for the error signals to be output at the ERRN (Pin-19) and ERRP (PIN-24) of the IO connector 2 (I/O2). Originally (in the default setting), the error output signals are the same as what are output to the red error LED positioned on the front panel. Therefore, depending on the error contents, the signals might become flashing. If you set this parameter to be Level signal, it is simply notified with the signal level whether or not any error exists.




Applicable values : Level signal / Same as error LED

JOBDEF error control

Description : Specify whether or not an error shall be caused in case no JOBDEF file exists at the time when the system starts.




Applicable values : Error not to be caused / Error to be caused

Real time error control

Description : Specify whether or not the system task shall get stopped when a real time error happens.




Applicable values : Not stop the system task / Stop the system task

Network address

Description : It shows the ArcNet controller address. Define the address when multiple Controllers are connected in the network of ArcNet. Use hexadecimal numbers from E0 to FF to define it. The default setting value is FF. For the 2nd and 3rd Controllers, you may as well specify them to be FE and FD, respectively.

Setting Not used : Impossible



Applicable values : E0～FF


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Output port during system task

Description : A special signal, which turns on while the system task is in operation, can be output. It defines the output port number for the signal.




Applicable values : Output port number (In the case of the standard I/O ports, the output ports are from 17 to 24)

Control for speed override Description : You can use the speed override even on the Remote mode if

you select Enable to control for Speed Override in remote mode. The speed override keys are displayed on the Remote mode as screen as shown below.

: You can change by the 10% incre-/decre-ment respectively, and the minimum value is 10%, therefore 0% is not allowed.




Version of the applicable Pendant


Default values : Not used

Changing the speed override

Override 100%


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Output port during system task

Description : You can reduce the number of DeviceNet I/O ports to shorten the reflesh cycle time, The default setting is the number of total:1024 points(inputs:512/outputs:512).

Setting #of #of #of Input Output

Value Total Inputs Outputs Port# Port#

1 64 32 32 6145-6176 6657-6688

2 128 64 64 6145-6208 6657-6720

3 256 128 128 6145-6272 6657-6784

4 512 256 256 6145-6400 6657-6912

5 1024 512 512 6145-6656 6657-7168




Applicable values : 1,2,3,4,5


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2. On the Pendant page

The output keys in the Teach mode on the Pendant usually can control one port only, as shown below.

But if you specify the parameters of OUT1, OUT2, --- OUT4 from the left to right in due order as shown above, you can control up to 8 ports at the same time when pushing each key. You set names, which are displayed on the keys, on the Port Name on Pendant, the port numbers on the Pot No. and 1(On)/0(Off) information on the On/Off. 1(On)/0(Off) information must be corresponded to LED on state and the first port must be set to On(1). When the button is pressed, the LED is turned on and the ports are outputted according to the Port No. and the On/Off information on the Pendant page. If you press the same button again, the ports are outputted in reverse. The each output is toggled on and off in turn.

The name of the key consists of 2 lines. You can put 5 characters on the first line, and 6 characters on the second line. (The first line is less one character than the second line, because of the LED character space.) Put a semicolon” ; ” between the first line and second line to specify the lines on the Port Name on Pendant.

■OUT4 0020

□OUT3 0019

□OUT1 0017

□OUT2 0018

□OUT5 0021

OUT1 OUT2 OUT3 OUT4


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For example, if you set the parameters as the above figure, the output buttons are displayed below. If you press RRVacOn key, the port 217(port number) becomes on, the port 218 becomes off and LED becomes turned on. Moreover, press the key once more, the port 217 becomes off, the port 218 becomes on, and LED becomes turned off.

(Remarks) Out5 button becomes the fixed formed button which indicates this function is used. Not Used is default setting at delivery of the machine from the manufacturer. Please take off the check from the box, input the parameters and press the OK button. Then changed the HWDEF.cfg file is downloaded to the controller. As a result, the saved data becomes effective when the Controller gets turned on the next time. <The port initial status> When you enter the Teach mode on the Pendant, the system reads the current port

status automatically, so that LED indication reflects the current port status.

□RRVac ON

JOG OUT

■RLVacON

□OUT30019

■OUT40020


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3.On the Robot*_pendant page

Jog key of pendant (Assignment of the jog keys)

Description : Define the assignment for the jog keys of the Pendant. In the first data column (No.1), specify the axis number with the moving direction of the axis that moves when you press the Jog1+ button of the drawing shown on the right (To make the axis move in the minus direction, set the axis number with “-“). In the second data column (No.2), specify the axis number with the moving direction of the axis that moves when you press the Jog2+ button of the drawing. Likewise, set the No.3, No.4, No.5 and No.6 data columns for the jog keys of Jog3+, Jog4+, Jog5+, and Jog6+ buttons, respectively.

Jog2+

Jog1－

Jog2－

Jog1+

Jog3+

Jog3－

Jog6+

Jog5－

Jog6－

Jog5+

Jog4+

Jog4－


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Default values : (1, 2, -3, 4, 0, 0)

Pendant reference motion (To specify the lifting axis in the Pendant reference motion = “Move to” function)

Description : You can change the lifting axis in the Pendant reference motion (= “Move to” function). When the “Move Over” or “Jump To” is selected, the lifting axis specified by this setup moves at first to make its coordinate value “0”. Usually the Z-axis is specified by this setup. However, in such a case where a CCR type robot is used for a vertical working plane, changing the assignment may improve the teaching performance.

This setup is effective only for the reference motion (= “Move to” function), and it does not work for the “JMPM” command of SSL/E.




Applicable values : 1= To cause the lifting motion, and 0 = Not to cause the lifting motion

Axis name on pendant (Characters on the Pendant)

Description : You can change the names (characters) of the coordinate axes for the teach data indication and current position indication on the Pendant.

Specify the first axis, second axis - - - from the left to right in due order.




Applicable values : 2 characters or less. Place “:” at the end. You cannot place a null space instead.

Default values : (X:, Y:, Z:, S:)

Lifting elevation of reference motion

Description : You can specify the lifting elevation of the Pendant reference motion (= “Move to” function)

Specify the first axis, second axis - - - from the left to right in due order.




Default values : 0


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Display 8 axes on the Pendant Description : You can input and display up to 8 axes for the teach data on

the Pendant, regardless of the number of robot axes. Change the setup Not Used to Enable. (It had been set to Not Used before delivery of the machine from the manufacturer)

-The 8 axes data input or display can be used at ① The display of the teaching data in the teaching main

screen ② The MDI input screen in the Menu (Note) When the “Data Repl” key is pushed on main teach screen, the value of no axis portion is not replaced.



: 204.25 or later


: 4.30 or later


Direction of added jog key

Description : You can assign the jog key of7th and 8th-axis to Out1-4 button. Select the logic axis numbers of the operated axis by pressing the output button.

: There are 4 boxes alike the figure, which is shown below.

You can set the logic axis number to Out 1, Out 2--- and Out 4 from the left to right in due order as shown below.

: To operate the axis to minus direction, select the axis numbers with “ - “ sign. In case of 7 axes robot, select “0” for the extra key. The “0”selected key is not shown.

: You can also assign 1st - 6th axis there. However, in such case, you need to adjust not to overlap with the setup of Output button assignment.



: 204.25 or later


: 4.30 or later



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Added jog key name

Description : When you assign the jog key of 7th and/or 8th axis to the output button, you can set their names to be displayed.

: You can put 6 characters on each line, to 2 lines for one key. Put a semicolon “ ; “ to designate the end of a line.



: 204.25 or later


: 4.30 or later

Default values : Not Used

e.g.) To display alike the figure below;

Input alike following figure;

BEND-R UP

JOG OUT

BEND-RDOWN

BEND-LUP

BEND-LDOWN


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4. On the Robot* page

Min End of work space (mm, deg) Max End of work space (mm, deg)

Description : You can change the work space range of the robot on each logic axis. The unit is mm or deg, however, it depends on the logic axis of the robot. Be sure to understand the mechanical specification on the robot before you change them. <Note>

To be sure to get the work space you expect, for example, if you expect the work space range to be 400mm, set the maximum work space (Max End of work space) to 400.1mm.

Setting Not used : Impossible

Default values : According to the mechanical specification


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- Changing the work space range, which is shown above, is equal to

change the software limit for the robot motion. Therefore, inputting a wrong value may cause some critical condition because the software limit might not work any more. Be sure to understand specifications of the robot.

ABS Homing sequence Description : You can define the ABS homing sequence by setting the

sequence number to the logic axis. Put “1” to the logic axis which moves first, and “2” to the next

axis, --- in this way, input the sequential numbers which are indicating the moving order. If you put the same numbers, the axes move at the same time.

: For example, If you set; 1, 2, 2, 2, 3 The Th1-axis returns first, and next, the Th2-4 start the homing motion at the same time. Then Th2-4 axes return to the home position. Lastly, Th5-axis starts homing.

Setting Not used : Impossible Default values : According to the mechanical specification

CAUTION

- This operation changes the robot ABS homing sequence.

Therefore, inputting a wrong order may cause the robot or system damage. Be sure to understand the specifications of the robot and system before changing these parameters.

DANGER !


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Offset pulse for calibration Description : The offset pulses are added to the command pulses, and the

added pulses are outputted to each logic axis to move the robot. Therefore, After the motor replacement, you can adjust the taught point to the original position changing these offset pulses without re-teaching.

: Since the unit of this value is pulse, you need to know the mechanical specification to get the actual motion distance.

: Be sure to understand the mechanical specification before changing these offset pulses.

Setting Not used : Impossible Default values : Set before delivery of the machine from the manufacturer

- The above change effects the all motion position of the robot.

Therefore, inputting a wrong value may cause some critical condition. Be sure to understand the mechanical specifications of the robot.

SVON/SVOFF control (The mechanical brake) Description : Usually, you don not need to change this. Setting Not used : Impossible Default values : Set before delivery of the machine from the manufacturer

- The above change effects the robot motion control.

Therefore, the wrong setting may cause some critical condition. Be sure to understand the mechanical specifications of the robot.

DANGER !

DANGER !


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Tool offset Description : You cannot use this for the LCD handling robot. This is

available only for the SACARA robot and CCR-robot. Setting Not used : Possible Default values : Not used


Therefore, inputting a wrong value may cause some critical condition. Please consult with Sankyo before using this.

Shifting coordinate Description : You cannot use this for the LCD handling robot. It is

available only for the SACARA robot and a CCR-robot. Setting Not used : Possible Default values : Not used


Therefore, inputting a wrong value may cause some critical condition. Please consult with Sankyo before using this.

Error analysis buffering mode Description : You can use this function for making an analysis for any

error. On the Controller, the specified data is buffered in the RAM buffer all the time. If any error comes up and the servo power is turned off, the buffering is stopped. And then, the data is uploaded and analyzed by 3000SPWin on PC. Please consult with Sankyo about the details if required.

Setting Not used : Possible Default values : Not used

DANGER !

DANGER !