r-j3ib handlingtool operator manual [b-81464en-2_02]

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OPERATORS MANUAL

B-81464EN-2/02

R-J3*B CONTROLLER

HANDLING TOOL

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B81464EN2/02 Table of Contents

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1. INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Manual Plan 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Workers 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 General Safety Precautions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Safety Precautions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. OVERVIEW 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Handling Tool Software 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 System setting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Jog feed of the robot 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3 Program 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.4 Test operation (test execution) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.5 Automatic operation (operation execution) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Robot 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Controller 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Teach pendant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1.1 Display screen of the teach pendant 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Operator panel 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Remote controller 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 CRT/KB 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5 Communication 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.6 Input/output 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.7 Peripheral I/O 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.8 Motion of the robot 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.9 Emergency Stop devices 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.10 Extended axis 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. SETTING UP THE HANDLING SYSTEM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 I/O 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Digital I/O 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Group I/O 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Analog I/O 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Robot I/O 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Peripheral I/O 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Operators Panel I/O 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 I/O Link Screen 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1 I/O Link list screen 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Model B unit list screen 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Signal count setting screen 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 I/O Connection Function 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Setting Automatic Operation 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1 Robot service request (RSR) 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Program number selection (PNS) 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Setting Coordinate Systems 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Setting a tool coordinate system 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Setting a user coordinate system 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Setting a jog coordinate system 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Setting a Reference Position 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 Joint Operating Area 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 User Alarm 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 Variable Axis Areas 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.13 Special Area Function 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 System Config Menu 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 Setting the General Items 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 Other Settings 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PROGRAM STRUCTURE 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Program Detail Information 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Program name 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Program comment 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Subtype 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Group mask 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Write protection 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6 Interruption disable 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Line Number, Program End Symbol, and Argument 134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Motion Instructions 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Motion format 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Position data 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Feedrate 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.4 Positioning path 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.5 Additional motion instructions 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.6 Highprecision locus function (option) 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Palletizing Instructions 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Palletizing instruction 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Palletizing motion instruction 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3 Palletizing end instruction 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Register Instructions 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Register instructions 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Position register instructions 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.3 Position register axis instructions 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4 Arithmetic palletizing register instructions 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 I/O Instructions 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 Digital I/O instructions 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 Robot I/O instructions 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.3 Analog I/O instructions 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.4 Group I/O instruction 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Branch Instructions 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 Label instruction 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.2 Program end instruction 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.3 Unconditional branch instructions 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.4 Conditional branch instructions 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.5 Arguments 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Wait Instructions 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.1 Timespecified wait instruction 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.2 Conditional wait instructions 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Skip Condition Instruction 188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Offset Condition Instruction 190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Tool Offset Condition Instructions 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Frame Instructions 192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 Program Control Instructions 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13.1 Halt instruction 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13.2 Abort instruction 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14 Other Instructions 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.14.1 RSR instruction 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.2 User alarm instruction 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.3 Timer instruction 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.4 Override instruction 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.5 Comment instruction 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.6 Message instruction 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.7 Parameter instruction 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.8 Maximum speed instructions 199. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15 Multiaxis Control Instructions 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.1 Semaphore instruction 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.2 Semaphore wait instruction 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.3 Program execution instruction 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16 Operation Group Instructions 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16.1 Asynchronous operation group instruction 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16.2 Synchronous operation group instruction 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. PROGRAMMING 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Tips on Effective Programming 205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Motion instructions 205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Predefined position 207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Turning on the Power and Jog Feed 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Turning on the power and turning off the power 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 ThreeMode Switch 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3 Moving the robot by jog feed 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Creating a Program 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Registering a program 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Changing a standard motion instruction 228. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Teaching a motion instruction 230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.4 Teaching an supplementary motion instruction 232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.5 Teaching a control instruction 236. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.6 TP start prohibition 241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Changing a Program 243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Selecting a program 243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Changing a motion instruction 245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Changing a control instruction 254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Program edit instructions 255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Program Operation 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Changing program information 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Background Editing 275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Singular Point Check Function 284. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. EXECUTING A PROGRAM 285. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Program Halt and Recovery 286. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Halt by an emergency stop and recovery 287. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Halt by a hold and recovery 288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3 Halt caused by an alarm 289. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Executing a Program 292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Starting a program 292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2 Robot motion 293. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.3 Resuming a program 295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Testing 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Specifying test execution 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Step test 302. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 Continuous test 305. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


c4

6.3.4 Program look/monitor 307. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Manual I/O Control 308. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 Forced output 308. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2 Simulated I/O 309. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.3 Standby release 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Operating the Hand Manually 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Automatic Operation 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 Automatic operation by robot start request (RSR) 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.2 Automatic operation with program number selection (PNS) 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.3 External override selection function 318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Online Position Modification 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. STATUS DISPLAY 326. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 LEDs on the Teach Pendant 327. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 User Screen 328. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Registers 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Position Registers 331. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Palletizing Registers 334. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Current Position 335. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 System Variables 337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Program Timer 338. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 System Timer 340. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Execution History 341. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 Memory Use Status Display 343. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. FILE INPUT/OUTPUT 344. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 File Input/Output Units 345. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Memory card 346. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.2 External memory unit 347. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.3 Floppy cassette adapter 348. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.4 Handy file 350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Setting a Communication Port 353. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Files 357. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1 Program file 357. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2 Default logic file 357. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.3 System file/application file 358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.4 Data file 358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.5 ASCII file 358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Saving Files 359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Saving with program selection screen 359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Saving all the program files using the file screen 361. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3 Saving with a function menu 364. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.4 File manipulation 366. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.5 ASCII save 368. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Loading Files 371. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Loading using the program selection screen 372. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Loading a specified program file using the file screen 373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Printing Files 378. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 Printer 378. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.2 Printing files 380. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B81464EN2/02

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8.7 Automatic Backup 383. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Overview of Automatic Backup 383. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2 Usable Memory Cards 383. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3 Setting of Automatic Backup 384. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4 Perform Automatic backup 385. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.5 Version management 385. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.6 Restore the backup 386. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. UTILITY 387. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Macro Instruction 388. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.1 Setting macro instructions 389. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2 Executing macro instructions 394. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Shift Functions 398. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.1 Program shift function 399. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.2 Mirror shift function 404. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.3 Angleinput shift function 408. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Coordinate System Change Shift Functions 413. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Soft Float Function 418. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Continuous Rotation Function 423. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Position Register LookAhead Execution Function 427. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 Operation Group DO Output Function 429. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 PreExecution Instruction Function 431. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 Distance before operations 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9.1 Overview 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.2 Specification 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.3 Configuration 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.4 Instruction 436. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.5 Entering Distance Before 444. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.6 Caution and limitations 446. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.7 System Variables 447. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.8 Error Codes 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.10 State Monitoring Function 450. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 Automatic Error Recovery Function 457. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11.1 Overview 457. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.2 Outline of the automatic error recovery function 457. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.3 Defining a resume program 460. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.4 Teaching the RETURN_PATH_DSBL instruction 461. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.5 Setting the automatic error recovery function 462. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.6 Flowchart for resuming a suspended program 469. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.7 Manual operation screen of the automatic error recovery function 470. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.8 Execution of the resume program from the teach pendant and test mode 472. . . . . . . . . . . . . . . . . . . . . . . 9.11.9 Changing conditions for executing the resume program 472. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.10 Other specifications and restrictions 472. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.11 Warnings 473. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.12 Remote TCP function 474. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Summary 474. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.2 Setup 477. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.13 HIGHSENSITIVITY COLLISION DETECTION 480. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.1 Overview 480. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.2 Specification 480. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.3 HighSensitivity Collision Detection 480. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.4 Cautions 481. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.14 LOAD SETTING 482. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


c6

9.14.1 Overview 482. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.2 Motion Performance Screens 482. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.3 Program Instructions 483. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.15 LOAD ESTIMATION 485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.1 Overview 485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.2 Operating Procedure 485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.3 Load Estimation Procedure (for 6Axis Robots) 485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.4 Calibration Procedure (for 6Axis Robots) 488. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.5 Other Related Matters 490. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.16 COLLISION DETECTION for AUXILIARY AXIS 492. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16.1 General 492. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16.2 CAUTION 492. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16.3 INITIAL SETTING 492. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16.4 TUNING PROCEDURE 492. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.17 Gravity Compensation 494. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17.1 System Variables 494. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17.2 MOTION Screen 494. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18 Servo Tool Change Function 496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1 OUTLINE 496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.1.1 Feature of function 496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1.2 Basic specification 496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1.3 Restrictions 496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1.4 System Configuration 497. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1.5 Outline of installation 498. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.2 INITIAL SETUP 499. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.3 PRELIMINARY TOOL ATTACH OPERATION 499. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.4 TOOL CHANGE SETUP 501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.5 SETTING THE REFERENCE POSITION 506. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.5.1 Batteryless type tools 506. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.5.2 Batterymounted type tools 506. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.6 TOOL CHANGE INSTRUCTION 507. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.6.1 TOOL DETACH instruction 507. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.6.2 TOOL ATTACH instruction 507. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.6.3 Sample program 507. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.6.4 Foward execution 508. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.6.5 Backward execution 508. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.7 TOOL CHANGE SEQUENCE 509. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.8 TOOL CHANGE STATUS 510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.9 TEACHING 511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.9.1 Notice for teaching 511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.9.2 Sample program 511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.10 Construction of Servo Tool change screen 512. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.11 TOOL CHANGE INITIAL SETUP 513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.11.1Setting Motion Parameters For Servo Tool Axes 513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.11.2Assigning Tool Numbers to Servo Tool Axes 513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18.12 Tool Change Reference Position Setup Method (batteryless type) 514. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.12.1Reference Position Setup for Calibration Types 3 and 4 514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.12.2Reference Position Setup for Calibration Types 5 and 6 516. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.12.3Quick Mastering Reference Position Setup 517. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B81464EN2/02

c7

9.18.13 Troubleshooting 518. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.13.1The attach instruction is executed when the tool is not attached 518. . . . . . . . . . . . . . . . . . . . . . . . 9.18.13.2The robot stopped during calibration 518. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.13.3Calibration motion failed 519. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.13.4A different tool from that specified by the attach instruction is attached 519. . . . . . . . . . . . . . . . . . 9.18.13.5The attached tool has been detached by mistake (without using the detach instruction) 520. . . . . . 9.18.13.6The tool axis of a detached tool has moved 520. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.13.7The battery voltage has fallen 521. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.13.8The battery ran low while the tool was detached 521. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.PALLETIZING FUNCTION 522. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Palletizing Function 523. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Palletizing Instructions 525. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Teaching the Palletizing Function 527. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3.1 Selecting a palletizing instruction 528. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.2 Inputting initial data 529. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.3 Teaching a stacking pattern 535. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.4 Setting path pattern conditions 541. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.5 Teaching a path pattern 544. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.6 Notes on teaching the palletizing function 547. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4 Executing the Palletizing Function 548. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.1 Palletizing register 549. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.2 Controlling the palletizing function by a palletizing register 550. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5 Modifying the Palletizing Function 551. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 Palletizing Function with Extended Axes 553. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 Palletizing AllPoint Teaching 554. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX

A. APPENDIX 559. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1 List of Menus 560. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2 Types of Screens 564. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3 List of Program Instructions 583. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4 Program Instructions 587. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.4.1 Motion instructions 587. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.2 Additional motion instructions 587. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.3 Register and I/O instructions 589. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.4 Conditional branch instructions 591. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.5 Wait instruction 592. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.6 Unconditional branch instructions 592. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.7 Program control instructions 593. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.8 Other instructions 593. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.9 Skip and Offset condition instruction 594. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.10 Frame setup instruction 595. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.11 Macro instruction 595. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.12 Multiaxis control instructions 595. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.13 Position register lookahead execution instruction 596. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.14 Soft float instruction 596. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.15 Status monitoring instructions 596. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.16 Motion group instructions 596. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.17 Palletizing instructions 597. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


c8

B. APPENDIX 598. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1 Start Mode 599. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1.1 Start up methods 599. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.2 Initial start 600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3 Controlled start 601. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.4 Cold start 603. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.5 Hot start 604. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 Mastering 605. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1 Jig mastering 607. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.2 Mastering at the zerodegree positions 609. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3 Quick mastering 611. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.4 Single axis mastering 614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.5 Setting mastering data 617. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 Software Version 619. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4 Robot Axis Status 621. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5 Diagnosis Screen 627. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.5.1 Outline 627. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.2 About Reducer Diagnosis 627. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.3 Procedure 628. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.4 Each item 629. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.6 World Frame Origin 632. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7 I/O Module Setting 633. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8 Positioner setup 638. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9 Extended Axis Setup 644. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10 Extended Axis Setup 649. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11 Independent Additional Axis Board (Nobot) Startup Procedure 654. . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. ALARM CODES 658. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.1 Description of an Alarm Code Table 659. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.2 Alarm Codes 666. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D. SYSTEM VARIABLES 774. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.1 Format of a System Variable Table 775. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.2 System Variables 777. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B81464EN2/02 1. INTRODUCTION

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1. INTRODUCTION

This chapter explains the manual plan and the safety precautions that must be observed in working with theFANUC Robot.

Contents of this chapter1.1 Manual Plan1.2 Workers1.3 General Safety Precautions1.4 Safety Precautions

1. INTRODUCTION B81464EN2/02

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1.1 Manual PlanFANUC Robot series (RJ3iB CONTROLLER) HANDLING TOOL Operators Manual.This manual describes how to operate the FANUC Robot, an allpurpose compact robot. It is controlled by theFANUC RJ3iB controller (called the robot controller hereinafter) containing the Handling tool software.This manual describes the following items for mainpulating workpieces with the robot: Setting the system for manipulating workpieces Operating the robot Creating and changing a program Executing a program Status indications Alarm codes and system variables

Using this manualEach chapter of the manual describes a single operation of the robot. The user can select and read chaptersdescribing required operations. The user can understand all the information presented in this the manual in fiveor six hours if he or she reads it from cover to cover once.

Chapter 1Introduction

Describes how to use this manual and the safety precautions that must beobserved in working with the robot. All users must read the safety precau-tions.

Chapter 2Overview

Gives a basic knowledge of the robot. It describes the basic configurationof the robot and the system for manipulating workpieces.

Chapter 3Setting the System for Manip-ulating Workpieces

Describes the procedure for setting the system for Manipulating Work-pieces including input/output, coordinate system, and reference position.

Chapter 4Program Structure Describes the program structure and the syntax of program instructions.

Chapter 5Creating a Program

Describes how to design, create, change, delete, and copy a program. Italso describes the procedures for turning the power on and moving therobot by jog feed.

Chapter 6Executing a Program

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

Chapter 7Status Indications

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

Chapter 8File Input/Output Describes how to store, read, and print a program file or system file.

Chapter 9Utility

Describes additional utility functions, macro functions, program shift andmirror shift.

Chapter 10Utility Describes the setting and executing of palletizing function.

Appendix Describes lists of the menus, screens, program instructions and detail ofprogram.Alarm Codes and SystemVariables Lists the alarm codes and system variables.


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IdentificationFor editions and order files of software, read the following sections:

Item to be checked SectionEdition of your software B.3 Software VersionOrder No. of your software A.1 List of Menus

Specifications of productsFor memory statuses or software option list, see the following sections:

Item to be checked SectionMemory status 7.11 Memory Use Status DisplaySoftware option list A.1 List of MenusMenu displayed when an option is selected A.1 List of MenusProgram instruction that can be used when an option is selected A.3 List of Program Instructions

Related manualsThe following manuals are available:

R-J3iBcontroller

OPERATORSMANUALHANDLINGTOOLB81464EN2

Intended readers:Operators responsible for designing, introducing, operating, andadjusting 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.

MAINTENANCE MANUALB81465EN

Topics:Installing and activating the system, connecting the mechanical unit tothe peripheral device and maintenance the robot.

Mechanical unit Maintenancemanual B81465EN

Topics:Installing and activating the robot, connecting the mechanical unit tothe controller, maintaining the robot.Use:Guide to installation, activation, connection, and maintenance.


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NotationThis manual contains safety precautions against injury and property damage. Those precautions are labelledWarning or Caution, according to the degree of importance. Supplementary explanation is given underNote. Before starting to use a robot, carefully read the Warning, Caution, and Note.

WARNINGFailure to follow the instruction given under Warning can cause fatal or serious injury to the user.This information is indicated in bold type in a box so that it can be easily distinguished from themain body of this manual.

CAUTIONFailure to follow the instruction given under Caution can cause injury to the user or property damage.This information is indicated in a box so that it can be easily distinguished from the main body of thismanual.

NOTE The information given under Note is a supplementary explanation, which is neither a warning nor acaution.

Carefully read and save this manual.


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1.2 WorkersA robot cannot do anything alone. The robot can operate only after it is equipped with a hand or other deviceand connected with peripheral equipment to form a system.Give considerations for the safety of not only the robot but also the entire system. When using the robot, providea safety fence and other safety measures. FANUC defines the system personnel as indicated below. Checkwhich worker should be trained in a specialist robot course.OperatorThe jobs of an operator are: Turning on and off the system Starting and stopping programs of a robot Recovering the system from an alarm state

The operator must not enter the area enclosed by the safety fence to do his or her work.Programmer or teaching operatorThe jobs of the programmer or teaching operator include the jobs of the operator and the following: Teaching of a robot, adjustment of the peripheral equipment, and other work that must be done in the area

enclosed by the safety fenceThe programmer or teaching operator should be trained in a specialist robot course.Maintenance engineerThe jobs of the maintenance engineer include the jobs of the programmer and the following: Repair and maintenance of the robot

The maintenance engineer should be trained in a specialist robot course.


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1.3 General Safety PrecautionsThis section lists general safety precautions. Before starting to use the robot, read the precautions. Thesubsequent sections of the manual indicate other precautions. Take each of the precautions.

General rulesWARNING 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 humidities. 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.)

WARNING Robot personnel must wear the following safety articles: Clothing suitable for each job Safety shoes Helmet

NOTE Programmers and maintenance staff should be trained in a suitable course at FANUC.

Notes on installation

WARNING 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.

CAUTION In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, thespeed should be gradually increased to check the operation of the robot.

Notes on operationWARNING 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 shouldbe eliminated before the operation.

CAUTION Operators should be ungloved while manipulating the operators panel or teach pendant. Operation with glovedfingers could cause an operation error.

NOTE Programs, system variables, and other information can be saved on memory card or floppy disks. Be sure tosave the data periodically in case the data is lost in an accident. (See the file input/output section for saving thedata.)


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Notes on programmingWARNING 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.CAUTION After programming is completed, a text execution should be given according to a specified procedure. (See the

section of program execution on this manual). During the text execution, workers must stay out of the safetyfence.

NOTE Programmers should be trained in a suitable course at FANUC.

Notes on maintenanceWARNING During maintenance, the robot and system should be in the poweroff state. If the robot or system is in the

poweron state, a maintenance operation could cause a shock hazard. If necessary, a lock should be providedto prevent any other person from turning on the robot or system. If maintenance needs to be executed in thepoweron state, the emergency stop button should be pressed.

WARNING When replacing a part, the maintenance worker should read the maintenance manual and learn the replacementprocedure beforehand. If a wrong procedure is followed, an accident may occur, causing damage to the robotand injury to the worker.

WARNING When entering the area enclosed by the safety fence, the maintenance worker should check the entire systemto make sure that no dangerous situations are present. If the worker needs to enter the area of the fence whilea dangerous situation exists, the worker should always take extreme care and check the current system status.

WARNING A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damagewould occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may causea fire.

WARNING When a motor or brake is removed, the robot arm should be supported with a crane or other equipmentbeforehand so that the arm would not fall during the removal.

WARNING If a robot motion is necessary during maintenance, the following precautions should be taken: Reserve an escape route. During the maintenance, always check the motions of the whole system so that

the escape route will not be blocked by the robot or peripheral equipment. Always pay attention to risk of dangerous situations and get prepared to press the emergency stop button

whenever necessary.WARNING When a motor, decelerator, 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.CAUTION Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls.

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

CAUTION The following parts are heated. If a maintenance worker needs to touch such a part in the heated state, theworker should wear heatresistant gloves or use other protective tools.

Servo motor Inside the control unit

CAUTION When a part is replaced, all bolts and other related components should put back into their original places. Acareful check must be given to ensure that no components are missing or left unmounted.

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


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CAUTION After a part is replaced, a text execution should be given for the robot according to a predetermined method.(See the program execution of this manual.) During the text execution, the maintenance staff should workoutside the safety fence.

CAUTION After the maintenance is completed, spilled oil or water and metal chips should be removed from the floor aroundthe robot and within the safety fence.

CAUTION When a part is replaced, care must be taken to prevent dust from entering the robot.

NOTE Each maintenance worker or inspection worker should be trained in a suitable course at FANUC.

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

NOTE The robot should be periodically inspected. (Refer to the maintenance manual.) A failure to do the periodicalinspection can adversely affect the performance or service life of the robot and also may cause an accident.


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1.4 Safety PrecautionsSafety precautionsUnlike ordinary automatic machines, robots have arms and wrists which can be moved in all operation space.A robot is quite flexible, but on the other hand, it is quite dangerous. The robot is usually connected withperipheral equipment to comprise an automated system. Users must take safety precautions for the entiresystem.The safety precautions are described below.Safety precautions related to installation and layout Use warning lamps and other provisions to indicate that the robot is operating.

Figure 11. Alarm Indications

Teaching Do not enter Danger

Put a protective fence with safety door around the system so that only the operator can enter the operatingarea by the door. Design the system so that it will stop when the door is opened.

NOTE Connect the *FENCE input signal to the safety door. Refer to the maintenance manual for explanationsabout how to connect.

NOTE When the *SFSPD (safety speed) input signal is turned off, the control unit halts the robot. Put a protective fence so that the motion range of the robot is surrounded completely. Moreover, put the

controller outside of the protective fence.

Improper installation

Proper installation

Install an emergency stop button where it will be readily accessible to the operator.NOTE Upon receiving an emergency stop signal, the controller immediately stops the robot.


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Figure 12. Safety Plug

Safety plugWhen the safety plug is removed, the contact opens.

Control circuit to stop the robot

* SFSPD input

+24E

Safety precautions related to system design Install a safety joint between robot wrists. If an abnormal external force is applied to the robot, the safety joint

breaks and the robot stops.NOTE When the hand break (*HBK) input signal goes off, the controller immediately stops the robot. Hand breakage detection can be disabled when the *HBK input signal is off. This can be set on the system

setting screen. See the section of the system config menu. Ground all peripheral units properly. When a desired operating area is smaller than the maximum operating area of the robot, the desired area

can be specified by parameters. The robot receives interlock signals sent from remote equipment. Upon receiving a signal indicating the

operating status of the remote equipment, the robot can stop or halt. When required, install a lock so that only authorized personnel can switch the power on.

NOTE The circuit breaker on the control unit door is designed such that poweron can be disabled by settinga padlock.

Figure 13. Locking the Circuit Breaker


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Safety precautions related to inspection and maintenance Before starting the inspection or maintenance, turn off the controller. Lock the circuit breaker or place a guard

to prevent someone else from switching the power on. Before disconnecting the pneumatic system, release the supply pressure. Before starting an inspection in which the electrical system of the robot need not be operated, press the

emergency stop button. When carrying out an inspection in which the robot needs to be operated, carefully observe the motion of

the robot. Immediately press the emergency stop button whenever required.

Figure 14. Emergency Stop Button

Emergency stop button

EMEGENCYSTOPON

OFFPORT

Emergency stop button

Safety precautions related to transportation When carrying the robot or another unit on a carrier such as a crane or fork lift, securely fasten the robot to

the carrier. Carefully inspect the crane, fork lift, other carrying equipment, and carrying handle on the product.

Figure 15. Carrying the Robot


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Safety precautions related to operation All robot system operators are requested to attend FANUC training courses to learn the safety precautions

and functions of the robot. Before beginning to program the robot, make sure that there are no abnormal or dangerous conditions

around the robot and peripheral equipment. Before working within the operating area of the robot, even when the robot is not running, switch the power

off or press the emergency stop button. Place a guard to prevent someone else from entering the operatingarea of the robot or activating the robot from the operators panel.

While programming the robot in its operating area, place a guard so that the robot can be immediatelystopped in an emergency.

Figure 16. Danger Monitoring by Two Persons

Table 11. Safety precautions itemOperator Workshop Transportation and installation

Avoid dangerous behavior. Wearworking clothes, safety shoes, anda safety helmet.

Keep the workshop neat, tidy, andclean. Install a protective fence andwarning indications. Provideventilation. Never bring flammablematerial to the workshop.

Keep the transportation lane freefrom obstacles. When carrying therobot or another unit on a carriersuch as a fork lift or crane, securelyfasten it to the carrier. Keep asufficient operating area. Makeconnection s properly.

Operation Maintenance and inspection HandAttend training classes. Master theoperating procedures. Excludeunauthorized personnel.

Use only FANUC products for repair.Before starting maintenance orinspection, turn the power off. Closethe controller door.

Inspect and take care of cables.Check the pneumatic pressure.Inspect the hand mechanism.

Figure 17. Safety Clothes and Safety Helmet

Before approaching the robot to program it, hold the teach pendant in your hand, press the deadman switch,and set the teach pendant enable switch on.

NOTE If the deadman switch is released while the teach pendant enable switch is on, the robot immediatelystops.


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Figure 18. Deadman switch and Teach pendant enable switch

Teach pendant enable switch

Deadman switch

Before moving the robot by jog feed, carefully observe the operation of the jog keys and the robot. Before moving the robot by jog feed, sufficiently lower the feedrate override of the robot.

2. OVERVIEW B81464EN2/02

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2. OVERVIEW

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

Contents of this chapter2.1 HandlingTool Software2.2 Robot2.3 Controller

B81464EN2/02 2. OVERVIEW

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A FANUC robot system consists of the tool software for manipulating workpieces, the mechanical unit of therobot itself (FANUC Robot series), and the Robot control unit.The robot system offers outstanding performance when manipulating automobile parts and other products.

Tool software for manipulating workpiecesThe tool software for manipulating workpieces is an application software package installed on the Robot controlunit. Any work can be performed by specifying menus and instructions from the teach pendant. The tool softwarefor manipulating workpieces contains instructions for controlling the robot, hands, remote control units, and otherperipheral devices.The I/O between an additional axis or control unit and another peripheral device can be controlled using the toolsoftware for manipulating workpieces. Other peripheral devices include cell controllers, floppy disk drives,printers, or vision sensors.RobotRobot has a hand or another end effector interface for control to do work. The FANUC robot is ideal formanipulating workpieces.ControllerThe Robot control unit supplies power to drive the mechanical unit.The tool software for manipulating workpieces is installed on the Robot control unit to control the teach pendant,operators panel, and external peripheral devices.Peripheral devices, including remote control units, are required to configure a system for manipulatingworkpieces. The remote control units are used to control the Robot control unit. The hands, floppy disk drive, printer, and other devices are operated using I/O and serial communication

units.Fig. 21 shows a typical robot system for manipulating workpieces. The system consists of a robot, the Robotcontrol unit, and peripheral devices.

Figure 21. Assembly system for car doors

Remote controller

Robotcontroller

Robotcontroller

Robot

Robot

Conveyor


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2.1 Handling Tool SoftwareThe Handling tool software has been specially designed to perform material handling operations. The Handlingtool software is contained in the Robot and enables the following: Setting up the system for material handling 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 beenhanced.

2.1.1 System settingThe Handling tool software has an interface for specifying parameters of operation of the manipulation system.(For how to set the handling system, see Chapter 3.)With the Handling tool software, the Handling, 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 otherperipheral units, the coordinate system, communication, and automatic operation.

2.1.2 Jog feed of the robotJog feed of the robot is the operation of moving the robot as desired by manually entering commands on theteach pendant. When a motion instruction of a program is executed, the robot is moved to the target position byjog feed, then the position is recorded. (For the jog feed of the robot, see 5.)

2.1.3 ProgramA 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 workis accomplished by sequentially executing the instructions.The Spot teach pendant is used to create or correct a program. (For creation of a program, see Chapter 5.) Theprogram contains the following instructions. Figure 23 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. Other instructions


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Figure 22. Handling Program

SAMPLE1 JOINT 10% 1/8 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: ABORT[End]

POINT TOUCHUP >

Program name

Line numberProgram instructions

Motion instruction

Macro instruction

End instructionProgram end symbol

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 checkthe program for normal operation. (For the test operation, see Sections 6.2 and 6.3.)The test execution of the program is one of the important steps in creating a good program. Before startingautomatic operation, execute the test program.

2.1.5 Automatic operation (operation execution)Automatic operation (operation execution) is the final step in executing programs. In automatic operation, thefollowing processing is executed: Specified programs are started one after another. (For automatic operation, see Sections 3.7 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.)


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2.2 Robot

A robot is a mechanical unit consisting of axes and arms driven by servo motors. A place at which arms areconnected 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 functionsas 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 rotatedabout one wrist axis and the end effector rotated about the other wrist axis.

Figure 23. Main axes and wrist axes

Figure 24. Hand with Fingers

Figure 25. Hand with Suction Cups and No Fingers


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2.3 ControllerRobot controller includes a power unit, user interface circuit, motion controlling circuit, memory circuit, andinput/output circuit.The user should use a teach pendant and operators box to operate the control unit.The operation control circuit controls the servo amplifier which moves all the robot axes, including any additionalaxes, via the main CPU printed circuit board.The memory circuit can store programs and data set by the user in the CMOS RAM on the main CPU printedcircuit board.The input/output (I/O) circuit interfaces the controller with the peripheral units by receiving and sending signalsvia the I/O link cable and peripheral connecting cable. The remote input/output signal is used for communicationwith the remote controller.

Figure 26. Robot controller

RJ3iB controller Operator panel

Teach pendant

Three mode switch

The circuitry of the controller depends on the robot and the system it controls. For details, refer to themaintenance manual.


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2.3.1 Teach pendantThe teach pendant provides an interface between the Handling tool software and the operator. The teachpendant is connected to the PC board in the controller by a cable.The following operations can be performed using the teach pendant: Jog feed of the robot Program generation Test execution Actual work Status check

The teach pendant includes the following: Liquid crystal display of 40 characters by 16 lines 11 LEDs 61 keys

CAUTIONThe operator of the teach pendant should use gloves that would not cause any operation error.

The following switches are also provided:

Teach pendantenable switch

This switch enables or disables the teach pendant. When the teach pendant isdisabled, a jog feed, program generation, or test execution cannot be carried out.

Deadman switch DEADMAN SWITCH is used as an enabling device.When the teach pendant is enabled, this switch allows robot motion only while thedeadman switch is gripped. If you release this switch, the robot stops immediately.

Emergency stopbutton

When pressed, the emergency stop button immediately stops the robot.

Figure 27. Switches on the Teach Pendant

Emergencystop button

Teach pendantenable switch Deadman

switch

Figure 28 shows the teach pendant.


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Figure 28. Teach Pendant

FAULTPAUSEDSTEPBUSYRUNNING

JOINTXYZTOOL

OFF ON

MENUS key: Usethis key to displaythe menu screen.

Cursor keys: Use thesekeys to move the cursor.

STEP key: Use this key toswitch between stepexecution and cycle execu-tion.

RESET key: Use thiskey to clear the alarm.

BACK SPACE key: Use thiskey to delete the character ornumber immediately beforethe cursor.

ITEM key: Use this keyto select an item using itsnumber

ENTER key: Use thiskey to enter a numericvalue or to select an itemfrom the menu. Jog Speed keys: Use

these keys to adjust thespeed of the robot when it

moves.

FCTN key: Usethis key to displaythe supplementary

menu.

Program keys: Usethese keys to select

menu options.

HOLD key: Use thiskey to stop the robot.

FWD (forward) key: Usethis key to execute the

next program statement.

Jog keys: Use thiskey to move the robot

manually.

COORD (coordinate) key:Use this key to select thejog coordinate system or

select another group.

I/O ENBLPROD MODE

TEST CYC

POSN STATUS

SET UP

TOOL2

TOOL1

I/O

MOVEMENU

STATUS Key: Use this key to display the STATUSscreen.

TOOL Keys: Use thiskey to display the Tool 1screen and Tool 2screen.

I/O key: Use this key to displaythe I/O screen.

MOVE MENU keys: Notsupported currently.

POSN key: Use thiskey to display thePOSITION screen.

S

r-j3ib handlingtool operator manual [b-81464en-2_02]

Documents

robot io

group io

peripheral io

io link screen

digital io

analog io

io link list screen

setting coordinate systems