v6.10 r-j3ib lr handling tool operator manual.pdf

FANUC Robotics RJ3iB Mate ControllerLR Handling ToolOperators Manual

MAROIBLRH02021E REV. AB81524EN/01

This publication contains proprietary information of FANUC RoboticsNorth America, Inc. furnished for customer use only. No other uses areauthorized without the express written permission of FANUC RoboticsNorth America, Inc.

FANUC Robotics North America, Inc.3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253

The descriptions and specifications contained in this manual were in effectat the time this manual was approved for printing. FANUC RoboticsNorth America, Inc, hereinafter referred to as FANUC Robotics, reservesthe right to discontinue models at any time or to change specifications ordesign without notice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings,schematics, bills of material, parts, connections and/or procedures forinstalling, disassembling, connecting, operating and programming FANUCRobotics products and/or systems. Such systems consist of robots,extended axes, robot controllers, application software, the KARELprogramming language, INSIGHT vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained inone or more approved FANUC Robotics Training Course(s) be permittedto install, operate, use, perform procedures on, repair, and/or maintainFANUC Robotics products and/or systems and their respectivecomponents. Approved training necessitates that the courses selected berelevant to the type of system installed and application performed at thecustomer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used inaccordance with the instruction manual, may causeinterference to radio communications. As temporarilypermitted by regulation, it has not been tested forcompliance with the limits for Class A computing devicespursuant to subpart J of Part 15 of FCC Rules, which aredesigned to provide reasonable protection against suchinterference. Operation of the equipment in a residentialarea is likely to cause interference, in which case the user,at his own expense, will be required to take whatevermeasure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on aregularly scheduled basis at its headquarters in Rochester Hills, Michigan.For additional information contact

FANUC Robotics North America, Inc.Training Department3900 W. Hamlin Roadweb site: www.fanucrobotics.com

Send your comments and suggestions about this manual to:[email protected]

Copyright 2002 by FANUC Robotics North America, Inc.All Rights Reserved

The information illustrated or contained herein is not to be reproduced,copied, translated into another language, or transmitted in whole or in partin any way without the prior written consent of FANUC Robotics NorthAmerica, Inc.

AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,PalletTool, SOCKETS, SOFT PARTS SpotTool,TorchMate, and YagTool are Registered Trademarks of FANUCRobotics.

FANUC Robotics reserves all proprietary rights, including but not limitedto trademark and trade name rights, in the following names:

AccuFlowARC MateARC Mate Sr.IntelliTrakLaserToolMotionPartsPaintWorks IIPalletMateSureWeldTurboMove

This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to setit apart from other text.

CAUTIONInformation appearing under CAUTION concerns the protectionof equipment, software, and data. It is boxed to set it apartfrom other text.

NOTE Information appearing next to NOTE concernsrelated information or useful hints.

Conventions Used inthis Manual

Revised:11/20/01

TECHNICAL SUPPORT, FIELDSERVICES & ROBOT REPAIRPress 1 (24 Hours/365 Days)

Facsimile = 248-377-7463

PARTS & PART REPAIRPress 2 ("After Hours" Press 1)

Facsimile = (248) 377-7832

PRODUCT & SYSTEMSTRAINING

Press 3 (8am-5pm EST; M-F)Facsimile = 248-377-7367

MARKETING, SALES, &LITERATURE REQUESTS

Press 4 (8am-5pm EST; M-F)Facsimile = 248-377-7366

CUSTOMER RESOURCE CENTER1-800-47-ROBOT

www.fanucrobotics.com(Canada & United States: 1-800-477-6268) or (International: 011-1-248-377-7159)

Technical SupportHot-Line Service personneldispatch After-hours partssupport (8:00 p.m. to7:00 a.m.)

Marketing information Application review New robot product sales Systems solution sales

Parts for down robots Replenishment & repairorders Warranty partreplacement Robot software andPACs

Training classregistration Consultation for non-standard training classesor on-site requests

___________________For best call resultshave: Customer number (ifknown) Company name Your name Your phone & faxnumbers Robot & controller type F# or serial number ofrobot Hour meter reading (ifavailable Software type andedition Any error messagesand LED displays (ifapplicable) Your P.O., credit card,or receiving # forwarranty, down robot, orpreventive maintenanceservice orders

___________________For best call resultshave: Customer number (ifknown) Company name Your name Your phone & faxnumbers Part name & number (ifknown) F# or serial number ofrobot, if available (reqdfor warranty) P.O., credit card, orreceiving # for warranty,down units, or software Shipping & billingaddresses Reason for repair (anysymptoms, error codes,or diagnostic LEDs thatwere identified)

___________________For best call resultshave: Customer number (ifknown) Company name Your name Your phone & faxnumbers Your billing address Types of coursesneeded Special requirements Robot and controllertype Proposed schedules Number of peopleattending Student names (ifavailable) Method of payment(P.O., credit card, etc.)

___________________For best call resultshave: Company name Company address Your name Your phone & faxnumbers Description of your need

*NOTE: A RETURN AUTHORIZATION (RA) FROM PARTS IS REQUIRED BEFORE SHIPPING ANYMATERIAL BACK TO FANUC ROBOTICS FOR PROPER RECEIVING & TRACKING. F# IS LOCATED

ON THE ROBOT BASE OR OPERATION PANEL.

Revised 11/12/01

FANUC Robotics North America, Inc. 3900 West Hamlin Road Rochester Hills, Michigan 48309-3253 www.fanucrobotics.com

FANUC Robotics North America Customer Resource Center (cRc)

Aftermarket Support Solutions

Parts Solutions- customized spare part packages, individual spare part pricing and availability,

warranty parts, refurbished parts inventory, core part credit, 24 hour emergency service on down robots Certified Repair/Rebuild Solutions- certified repair/rebuild capabilities for over 500

different components and multiple controller product platforms completed in the Rochester Hills facility, authorized repair for North America, repaired with authentic FANUC parts, certified repair/rebuild serial identification, warranty identification tracked, core part credits on certified repairs *All certified repairs are backed by the same one-year warranty as a new FANUC Robotics part

Rebuild Services Levels

Level 1 Refurbishment Service- preventive maintenance service for robots with less than 10,000 servo hours

Level 2 Refurbishment Service-thorough diagnostic and maintenance service 10,000 - 30,000 servo hours

Rebuild Service- major overhaul service greater than 30,000 servo hours Rebuilt Robots- sale of certified rebuilt robots *All certified repairs are backed by the same one-year warranty as a new FANUC Robotics part

Training Solutions- Robot Operations Computer Based Training CD-Rom, over 50 courses available providing standard & customized training solutions that improve your ability to optimize and troubleshoot robot and system performance

NO Charge Web Solutions (Requires Registration)

cRc Parts Solutions- parts search engine, create/view parts quotes, submit order online, order tracking, multiple tracking options, order status (including backorder information), detailed shipment breakdowns, and a direct link to carriers website

Return Solutions- new or refurbished parts, certified component repairs, warranty orders by F numbers, core credit, printable return labels, online return tracking, authorization tracking number online, online credit value viewing

Customized Web Solutions

Electronic Documentation Solutions- engineering bulletins, products, operations, and maintenance manuals, multi-platform eDiagnostic tools DRC, minimize mean time to repair

Application Back-Up Solutions- scheduled on-site manual back-up, preventive maintenance schedules, customer direct uploads, cataloging by F numbers, automated network solutions, minimize mean time to repair

Technical Solutions- local / regional field service scheduling and dispatch to minimize response time,

reliability and maintainability studies, preventive maintenance, robot evaluations, system optimization, enhancement services / upgrades, in-plant resident service engineer

Customer Service Hotline 1-800-47-ROBOT (248) 377-7463

For more information, visit our website at: http://www.fanucrobotics.com/crc.asp

SafetyMAROIBLRH02021E REV A s1FANUC Robotics is not and does not represent itself as an expert in safetysystems, safety equipment, or the specific safety aspects of your companyand/or its work force. It is the responsibility of the owner, employer, oruser to take all necessary steps to guarantee the safety of all personnel inthe workplace.

The appropriate level of safety for your application and installation canbest be determined by safety system professionals. FANUC Roboticstherefore, recommends that each customer consult with such professionalsin order to provide a workplace that allows for the safe application, use,and operation of FANUC Robotic systems.

According to the industry standard ANSI/RIA R15.06, the owner or user isadvised to consult the standards to ensure compliance with its requests forRobotics System design, usability, operation, maintenance, and service.Additionally, as the owner, employer, or user of a robotic system, it is yourresponsibility to arrange for the training of the operator of a robot systemto recognize and respond to known hazards associated with your roboticsystem and to be aware of the recommended operating procedures for yourparticular application and robot installation.

FANUC Robotics therefore, recommends that all personnel who intend tooperate, program, repair, or otherwise use the robotics system be trained inan approved FANUC Robotics training course and become familiar withthe proper operation of the system. Persons responsible for programmingthe system-including the design, implementation, and debugging ofapplication programs-must be familiar with the recommendedprogramming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance ofsafety in the workplace.

SAFETY MAROIBLRH02021E REV As2

Safety is essential whenever robots are used. Keep in mind the followingfactors with regard to safety:

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider thefollowing:

People External devices Robot(s) Tooling Workpiece

Always give appropriate attention to the work area that surrounds therobot. The safety of the work area can be enhanced by the installation ofsome or all of the following devices:

Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

A safe workcell is essential to protect people and equipment. Observe thefollowing guidelines to ensure that the workcell is set up safely. Thesesuggestions are intended to supplement and not replace existing federal,state, and local laws, regulations, and guidelines that pertain to safety.

Sponsor your personnel for training in approved FANUC Roboticstraining course(s) related to your application. Never permit untrainedpersonnel to operate the robots.

Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.

Use anti-tie-down logic to prevent the operator from bypassing safetymeasures.

Arrange the workcell so the operator faces the workcell and can seewhat is going on inside the cell.

CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

SAFETYMAROIBLRH02021E REV A s3

Clearly identify the work envelope of each robot in the system withfloor markings, signs, and special barriers. The work envelope is thearea defined by the maximum motion range of the robot, including anytooling attached to the wrist flange that extend this range.

Position all controllers outside the robot work envelope.

Never rely on software as the primary safety element.

Mount an adequate number of EMERGENCY STOP buttons orswitches within easy reach of the operator and at critical points insideand around the outside of the workcell.

Install flashing lights and/or audible warning devices that activatewhenever the robot is operating, that is, whenever power is applied tothe servo drive system. Audible warning devices shall exceed theambient noise level at the end-use application.

Wherever possible, install safety fences to protect against unauthorizedentry by personnel into the work envelope.

Install special guarding that prevents the operator from reaching intorestricted areas of the work envelope.

Use interlocks.

Use presence or proximity sensing devices such as light curtains, mats,and capacitance and vision systems to enhance safety.

Periodically check the safety joints or safety clutches that can beoptionally installed between the robot wrist flange and tooling. If thetooling strikes an object, these devices dislodge, remove power fromthe system, and help to minimize damage to the tooling and robot.

Make sure all external devices are properly filtered, grounded,shielded, and suppressed to prevent hazardous motion due to theeffects of electro-magnetic interference (EMI), radio frequencyinterference (RFI), and electro-static discharge (ESD).

Make provisions for power lockout/tagout at the controller.

Eliminate pinch points. Pinch points are areas where personnel couldget trapped between a moving robot and other equipment.

Provide enough room inside the workcell to permit personnel to teachthe robot and perform maintenance safely.

Program the robot to load and unload material safely.

If high voltage electrostatics are present, be sure to provide appropriateinterlocks, warning, and beacons.

If materials are being applied at dangerously high pressure, provideelectrical interlocks for lockout of material flow and pressure.


Advise all personnel who must teach the robot or otherwise manuallyoperate the robot to observe the following rules:

Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery.

Know whether or not you are using an intrinsically safe teach pendantif you are working in a hazardous environment.

Before teaching, visually inspect the robot and work envelope to makesure that no potentially hazardous conditions exist. The workenvelope is the area defined by the maximum motion range of therobot. These include tooling attached to the wrist flange that extendsthis range.

The area near the robot must be clean and free of oil, water, or debris.Immediately report unsafe working conditions to the supervisor orsafety department.

FANUC Robotics recommends that no one enter the work envelope ofa robot that is on, except for robot teaching operations. However, ifyou must enter the work envelope, be sure all safeguards are in place,check the teach pendant DEADMAN switch for proper operation, andplace the robot in teach mode. Take the teach pendant with you, turn iton, and be prepared to release the DEADMAN switch. Only theperson with the teach pendant should be in the work envelope.

WARNINGNever bypass, strap, or otherwise deactivate a safetydevice, such as a limit switch, for any operationalconvenience. Deactivating a safety device is known tohave resulted in serious injury and death.

Know the path that can be used to escape from a moving robot; makesure the escape path is never blocked.

Isolate the robot from all remote control signals that can cause motionwhile data is being taught.

Test any program being run for the first time in the following manner:

WARNINGStay outside the robot work envelope whenever a programis being run. Failure to do so can result in injury.

Using a low motion speed, single step the program for at least onefull cycle.

Using a low motion speed, test run the program continuously forat least one full cycle.

Using the programmed speed, test run the program continuouslyfor at least one full cycle.

Make sure all personnel are outside the work envelope before runningproduction.

Staying Safe WhileTeaching or ManuallyOperating the Robot


Advise all personnel who operate the robot during production to observethe following rules:

Make sure all safety provisions are present and active.

Know the entire workcell area. The workcell includes the robot and itswork envelope, plus the area occupied by all external devices andother equipment with which the robot interacts.

Understand the complete task the robot is programmed to performbefore initiating automatic operation.

Make sure all personnel are outside the work envelope beforeoperating the robot.

Never enter or allow others to enter the work envelope duringautomatic operation of the robot.

Know the location and status of all switches, sensors, and controlsignals that could cause the robot to move.

Know where the EMERGENCY STOP buttons are located on both therobot control and external control devices. Be prepared to press thesebuttons in an emergency.

Never assume that a program is complete if the robot is not moving.The robot could be waiting for an input signal that will permit it tocontinue activity.

If the robot is running in a pattern, do not assume it will continue torun in the same pattern.

Never try to stop the robot, or break its motion, with your body. Theonly way to stop robot motion immediately is to press anEMERGENCY STOP button located on the controller panel, teachpendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

Turn off power at the controller.

Lock out and tag out the power source at the controller according tothe policies of your plant.

Turn off the compressed air source and relieve the air pressure.

If robot motion is not needed for inspecting the electrical circuits,press the EMERGENCY STOP button on the operator panel.


Staying Safe DuringAutomatic Operation

Staying Safe DuringInspection


If power is needed to check the robot motion or electrical circuits, beprepared to press the EMERGENCY STOP button, in an emergency.

Be aware that when you remove a servomotor or brake, the associatedrobot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.

When performing maintenance on your robot system, observe the following rules:

Never enter the work envelope while the robot or a program is inoperation.

Before entering the work envelope, visually inspect the workcell tomake sure no potentially hazardous conditions exist.


Consider all or any overlapping work envelopes of adjoining robotswhen standing in a work envelope.

Test the teach pendant for proper operation before entering the workenvelope.

If it is necessary for you to enter the robot work envelope while poweris turned on, you must be sure that you are in control of the robot. Besure to take the teach pendant with you, press the DEADMAN switch,and turn the teach pendant on. Be prepared to release the DEADMANswitch to turn off servo power to the robot immediately.

Whenever possible, perform maintenance with the power turned off.Before you open the controller front panel or enter the work envelope,turn off and lock out the 3-phase power source at the controller.


WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.

HIGH VOLTAGE IS PRESENT at the input side wheneverthe controller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removespower from the output side of the device only.

Release or block all stored energy. Before working on the pneumaticsystem, shut off the system air supply and purge the air lines.

Staying Safe DuringMaintenance


Isolate the robot from all remote control signals. If maintenance mustbe done when the power is on, make sure the person inside the workenvelope has sole control of the robot. The teach pendant must beheld by this person.

Make sure personnel cannot get trapped between the moving robot andother equipment. Know the path that can be used to escape from amoving robot. Make sure the escape route is never blocked.

Use blocks, mechanical stops, and pins to prevent hazardousmovement by the robot. Make sure that such devices do not createpinch points that could trap personnel.

WARNINGDo not try to remove any mechanical component from therobot before thoroughly reading and understanding theprocedures in the appropriate manual. Doing so can resultin serious personal injury and component destruction.


When replacing or installing components, make sure dirt and debris donot enter the system.

Use only specified parts for replacement. To avoid fires and damageto parts in the controller, never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the workenvelope; be sure that the robot and all external devices are operatingnormally.


Certain programming and mechanical measures are useful in keeping themachine tools and other external devices safe. Some of these measures areoutlined below. Make sure you know all associated measures for safe useof such devices.

Implement the following programming safety measures to prevent damageto machine tools and other external devices.

Back-check limit switches in the workcell to make sure they do notfail.

Implement failure routines in programs that will provide appropriaterobot actions if an external device or another robot in the workcellfails.

Use handshaking protocol to synchronize robot and external deviceoperations.

Program the robot to check the condition of all external devices duringan operating cycle.

Implement the following mechanical safety measures to prevent damage tomachine tools and other external devices.

Make sure the workcell is clean and free of oil, water, and debris.

Use software limits, limit switches, and mechanical hardstops toprevent undesired movement of the robot into the work area ofmachine tools and external devices.

KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Mechanical SafetyPrecautions


Observe the following operating and programming guidelines to preventdamage to the robot.

The following measures are designed to prevent damage to the robotduring operation.

Use a low override speed to increase your control over the robot whenjogging the robot.

Visualize the movement the robot will make before you press the jogkeys on the teach pendant.

Make sure the work envelope is clean and free of oil, water, or debris.

Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to the robotduring programming:

Establish interference zones to prevent collisions when two or morerobots share a work area.

Make sure that the program ends with the robot near or at the homeposition.

Be aware of signals or other operations that could trigger operation oftooling resulting in personal injury or equipment damage.

NOTE Any deviation from the methods and safety practices described inthis manual must conform to the approved standards of your company. Ifyou have questions, see your supervisor.

KEEPING THEROBOT SAFE

Operating SafetyPrecautions

Programming SafetyPrecautions


Process technicians are sometimes required to enter the paint booth, forexample, during daily or routine calibration or while teaching new paths toa robot. Maintenance personal also must work inside the paint boothperiodically.

Whenever personnel are working inside the paint booth, ventilationequipment must be used. Instruction on the proper use of ventilatingequipment usually is provided by the paint shop supervisor.

Although paint booth hazards have been minimized, potential dangers stillexist. Therefore, todays highly automated paint booth requires thatprocess and maintenance personnel have full awareness of the system andits capabilities. They must understand the interaction that occurs betweenthe vehicle moving along the conveyor and the robot(s), hood/deck anddoor opening devices, and high-voltage electrostatic tools.

Paint robots are operated in three modes:

Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic mode

During both teach and automatic modes, the robots in the paint booth willfollow a predetermined pattern of movements. In teach mode, the processtechnician teaches (programs) paint paths using the teach pendant.

In automatic mode, robot operation is initiated at the System OperatorConsole (SOC) or Manual Control Panel (MCP), if available, and can bemonitored from outside the paint booth. All personnel must remainoutside of the booth or in a designated safe area within the booth wheneverautomatic mode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they weretaught during teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines thatrequire them to remain in the paint booth, they must stay in a designatedsafe area.

ADDITIONALSAFETYCONSIDERATIONSFOR PAINT ROBOTINSTALLATIONS


Process technicians and maintenance personnel must become totallyfamiliar with the equipment and its capabilities. To minimize the risk ofinjury when working near robots and related equipment, personnel mustcomply strictly with the procedures in the manuals.

This section provides information about the safety features that areincluded in the paint system and also explains the way the robot interactswith other equipment in the system.

The paint system includes the following safety features:

Most paint booths have red warning beacons that illuminate when therobots are armed and ready to paint. Your booth might have otherkinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated,indicates that the electrostatic devices are enabled. Your booth mighthave other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controller andteach pendant. Become familiar with the locations of all E-STOPbuttons.

An intrinsically safe teach pendant is used when teaching in hazardouspaint atmospheres.

A DEADMAN switch is located on each teach pendant. When thisswitch is held in, and the teach pendant is on, power is applied to therobot servo system. If the engaged DEADMAN switch is releasedduring robot operation, power is removed from the servo system, allaxis brakes are applied, and the robot comes to an EMERGENCYSTOP. Safety interlocks within the system might also E-STOP otherrobots.

WARNINGAn EMERGENCY STOP will occur if the DEADMAN switchis released on a bypassed robot.

Overtravel by robot axes is prevented by software limits. All of themajor and minor axes are governed by software limits. Limit switchesand hardstops also limit travel by the major axes.

Paint System SafetyFeatures


EMERGENCY STOP limit switches and photoelectric eyes might bepart of your system. Limit switches, located on the entrance/exit doorsof each booth, will EMERGENCY STOP all equipment in the booth ifa door is opened while the system is operating in automatic or manualmode. For some systems, signals to these switches are inactive whenthe switch on the SCC is in teach mode.

When present, photoelectric eyes are sometimes used to monitorunauthorized intrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result inautomatic system shutdown.

When you work in or near the paint booth, observe the following rules, inaddition to all rules for safe operation that apply to all robot systems.

WARNINGObserve all safety rules and guidelines to avoid injury.

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

Know the work area of the entire paint station (workcell).

Know the work envelope of the robot and hood/deck and door openingdevices.

Be aware of overlapping work envelopes of adjacent robots.

Know where all red, mushroom-shaped EMERGENCY STOP buttonsare located.

Know the location and status of all switches, sensors, and/or controlsignals that might cause the robot, conveyor, and opening devices tomove.

Make sure that the work area near the robot is clean and free of water,oil, and debris. Report unsafe conditions to your supervisor.

Become familiar with the complete task the robot will performBEFORE starting automatic mode.

Make sure all personnel are outside the paint booth before you turn onpower to the robot servo system.

Staying Safe WhileOperating the PaintRobot


Never enter the work envelope or paint booth before you turn offpower to the robot servo system.

Never enter the work envelope during automatic operation unless asafe area has been designated.


Remove all metallic objects, such as rings, watches, and belts, beforeentering a booth when the electrostatic devices are enabled.

Stay out of areas where you might get trapped between a movingrobot, conveyor, or opening device and another object.

Be aware of signals and/or operations that could result in the triggeringof guns or bells.

Be aware of all safety precautions when dispensing of paint isrequired.

Follow the procedures described in this manual.

When you perform maintenance on the painter system, observe thefollowing rules, and all other maintenance safety rules that apply to allrobot installations. Only qualified, trained service or maintenancepersonnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Usecaution when working with electric tools.

When a maintenance technician is repairing or adjusting a robot, thework area is under the control of that technician. All personnel notparticipating in the maintenance must stay out of the area.

For some maintenance procedures, station a second person at thecontrol panel within reach of the EMERGENCY STOP button. Thisperson must understand the robot and associated potential hazards.

Be sure all covers and inspection plates are in good repair and in place.

Always return the robot to the home position before you disarm it.

Never use machine power to aid in removing any component from therobot.

During robot operations, be aware of the robots movements. Excessvibration, unusual sounds, and so forth, can alert you to potentialproblems.

Whenever possible, turn off the main electrical disconnect before youclean the robot.

Staying Safe DuringMaintenance


When using vinyl resin observe the following:

Wear eye protection and protective gloves during application andremoval

Adequate ventilation is required. Overexposure could causedrowsiness or skin and eye irritation.

If there is contact with the skin, wash with water.

When using paint remover observe the following:

Eye protection, protective rubber gloves, boots, and apron arerequired during booth cleaning.

Adequate ventilation is required. Overexposure could causedrowsiness.

If there is contact with the skin or eyes, rinse with water for atleast 15 minutes.

This manual describes the following products.

Name of product Abbreviation

FANUC Robot R2000i R2000i

B81524EN/01 Table of Contents

c1

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 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 LR Handling Tool Software 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 System setting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Jog feed of the robot 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3 Program 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.4 Test operation (test execution) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.5 Automatic operation (operation execution) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Robot 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Controller 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 CRT/KB 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5 Communication 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.6 Input/output 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.7 Peripheral I/O 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.8 Motion of the robot 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.9 Emergency Stop devices 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.10 Extended axis 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. SETTING UP THE HANDLING SYSTEM 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 I/O 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Digital I/O 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Group I/O 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Analog I/O 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Robot I/O 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Peripheral I/O 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Operators Panel I/O 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 I/O Link Screen 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 I/O Link list screen 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Model B unit list screen 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Signal count setting screen 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 I/O Connection Function 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Setting Automatic Operation 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Robot service request (RSR) 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Program number selection (PNS) 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Setting Coordinate Systems 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Setting a tool coordinate system 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Setting a user coordinate system 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Setting a jog coordinate system 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Setting a Reference Position 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Joint Operating Area 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 User Alarm 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 Variable Axis Areas 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.13 Preventive Interference Area Function 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14 System Config Menu 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15 Setting the General Items 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.16 Other Settings 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. PROGRAM STRUCTURE 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Program Detail Information 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Program name 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Program comment 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Subtype 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Group mask 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Write protection 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6 Interruption disable 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Line Number, Program End Symbol, and Argument 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Motion Instructions 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Motion format 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Position data 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Feedrate 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.4 Positioning path 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.5 Additional motion instructions 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.6 Highprecision locus function (option) 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Palletizing Instructions 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Palletizing instruction 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Palletizing motion instruction 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3 Palletizing end instruction 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Register Instructions 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Register instructions 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Position register instructions 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.3 Position register axis instructions 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4 Arithmetic palletizing register instructions 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 I/O Instructions 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 Digital I/O instructions 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 Robot I/O instructions 180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.3 Analog I/O instructions 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.4 Group I/O instruction 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Branch Instructions 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 Label instruction 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.2 Program end instruction 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.3 Unconditional branch instructions 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.4 Conditional branch instructions 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.5 Arguments 188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Wait Instructions 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.1 Timespecified wait instruction 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.2 Conditional wait instructions 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Skip Condition Instruction 198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 Offset Condition Instruction 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11 Tool Offset Condition Instructions 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12 Frame Instructions 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13 Program Control Instructions 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13.1 Halt instruction 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13.2 Abort instruction 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14 Other Instructions 204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.14.1 RSR instruction 204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.2 User alarm instruction 204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.3 Timer instruction 205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.4 Override instruction 205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.5 Comment instruction 205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.6 Message instruction 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.7 Parameter instruction 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.8 Maximum speed instructions 209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15 Multiaxis Control Instructions 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.1 Semaphore instruction 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.2 Semaphore wait instruction 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.3 Program execution instruction 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.16 Operation Group Instructions 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16.1 Asynchronous operation group instruction 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16.2 Synchronous operation group instruction 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. PROGRAMMING 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Tips on Effective Programming 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Motion instructions 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Predefined position 218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Turning on the Power and Jog Feed 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Turning on the power and turning off the power 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 ThreeMode Switch 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3 Moving the robot by jog feed 227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Creating a Program 234. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Registering a program 235. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Changing a standard motion instruction 239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Teaching a motion instruction 241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.4 Teaching an supplementary motion instruction 243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.5 Teaching a control instruction 247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.6 TP start prohibition 252. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Changing a Program 254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Selecting a program 254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Changing a motion instruction 256. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Changing a control instruction 265. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Program edit instructions 266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Program Operation 281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Changing program information 281. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Background Editing 286. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Singular Point Check Function 295. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. EXECUTING A PROGRAM 296. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Program Halt and Recovery 297. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Halt by an emergency stop and recovery 298. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Halt by a hold and recovery 299. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3 Halt caused by an alarm 300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Executing a Program 303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Starting a program 303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2 Robot motion 304. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.3 Resuming a program 306. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Testing 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Specifying test execution 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Step test 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 Continuous test 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


c4

6.3.4 Program look/monitor 319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Manual I/O Control 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Forced output 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2 Simulated I/O 321. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.3 Standby release 323. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Operating the Hand Manually 324. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 Automatic Operation 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.1 Automatic operation by robot start request (RSR) 326. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.2 Automatic operation with program number selection (PNS) 328. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.3 External override selection function 330. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Online Position Modification 332. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. STATUS DISPLAY 338. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 LEDs on the Teach Pendant 339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 User Screen 340. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Registers 341. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Position Registers 343. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 Palletizing Registers 346. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 Current Position 347. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 System Variables 349. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 Program Timer 350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 System Timer 352. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 Execution History 353. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 Memory Use Status Display 355. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. FILE INPUT/OUTPUT 356. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 File Input/Output Units 357. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Memory card 358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.2 External memory unit 359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.3 Floppy cassette adapter 360. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.4 Handy file 362. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Setting a Communication Port 365. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Files 369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Program file 369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2 Default logic file 369. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.3 System file/application file 370. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.4 Data file 370. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.5 ASCII file 370. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Saving Files 371. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Saving with program selection screen 371. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Saving all the program files using the file screen 373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3 Saving with a function menu 376. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.4 File manipulation 378. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.5 ASCII save 380. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Loading Files 383. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Loading using the program selection screen 384. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Loading a specified program file using the file screen 385. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Printing Files 390. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 Printer 390. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.2 Printing files 392. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B81524EN/01

c5

8.7 Automatic Backup 395. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Overview of Automatic Backup 395. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2 Usable Memory Cards 395. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3 Setting of Automatic Backup 396. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4 Perform Automatic backup 397. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.5 Version management 397. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.6 Restore the backup 398. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. UTILITY 399. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Macro Instruction 400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.1 Setting macro instructions 401. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2 Executing macro instructions 406. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Shift Functions 410. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.1 Program shift function 411. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.2 Mirror shift function 416. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.3 Angleinput shift function 420. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Coordinate System Change Shift Functions 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Soft Float Function 430. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Continuous Rotation Function 435. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Position Register LookAhead Execution Function 439. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.7 Operation Group DO Output Function 441. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.8 PreExecution Instruction Function 443. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9 Distance before operations 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Overview 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.2 Specification 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.3 Configuration 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.4 Instruction 448. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.5 Entering Distance Before 456. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.6 Caution and limitations 458. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.7 System Variables 459. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.8 Error Codes 460. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.10 State Monitoring Function 462. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11 Automatic Error Recovery Function 469. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Overview 469. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.2 Outline of the automatic error recovery function 469. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.3 Defining a resume program 472. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.4 Teaching the RETURN_PATH_DSBL instruction 473. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.5 Setting the automatic error recovery function 474. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.6 Flowchart for resuming a suspended program 481. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.7 Manual operation screen of the automatic error recovery function 482. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.8 Execution of the resume program from the teach pendant and test mode 484. . . . . . . . . . . . . . . . . . . . . . . 9.11.9 Changing conditions for executing the resume program 484. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.10 Other specifications and restrictions 484. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.11 Warnings 485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.12 HIGHSENSITIVITY COLLISION DETECTION 486. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Overview 486. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.2 Specification 486. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.3 HighSensitivity Collision Detection 486. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.4 Cautions 487. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.13 LOAD SETTING 488. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.1 Overview 488. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.2 Motion Performance Screens 488. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.3 Program Instructions 489. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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9.14 COLLISION DETECTION for AUXILIARY AXIS 491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.1 General 491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.2 CAUTION 491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.3 INITIAL SETTING 491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.4 TUNING PROCEDURE 491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.15 Gravity Compensation 493. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.1 System Variables 493. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.2 MOTION Screen 493. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.PALLETIZING FUNCTION 495. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Palletizing Function 496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Palletizing Instructions 498. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Teaching the Palletizing Function 500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.1 Selecting a palletizing instruction 501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.2 Inputting initial data 502. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.3 Teaching a stacking pattern 508. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.4 Setting path pattern conditions 514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.5 Teaching a path pattern 517. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.6 Notes on teaching the palletizing function 520. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4 Executing the Palletizing Function 521. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.1 Palletizing register 522. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.2 Controlling the palletizing function by a palletizing register 523. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5 Modifying the Palletizing Function 524. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.6 Palletizing Function with Extended Axes 526. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7 Palletizing AllPoint Teaching 527. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX

A. APPENDIX 531. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1 List of Menus 532. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Types of Screens 536. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.3 List of Program Instructions 555. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.4 Program Instructions 559. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.1 Motion instructions 559. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.2 Additional motion instructions 559. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.3 Register and I/O instructions 561. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.4 Conditional branch instructions 563. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.5 Wait instruction 564. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.6 Unconditional branch instructions 564. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.7 Program control instructions 565. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.8 Other instructions 565. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.9 Skip and Offset condition instruction 566. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.10 Frame setup instruction 567. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.11 Macro instruction 567. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.12 Multiaxis control instructions 567. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.13 Position register lookahead execution instruction 568. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.14 Soft float instruction 568. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.15 Status monitoring instructions 568. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.16 Motion group instructions 568. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.17 Palletizing instructions 569. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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B. APPENDIX 570. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1 Start Mode 571. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1.1 Start up methods 571. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.2 Initial start 572. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3 Controlled start 573. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.4 Cold start 575. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.5 Hot start 576. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 Mastering 577. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1 Jig mastering 579. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.2 Mastering at the zerodegree positions 581. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3 Quick mastering 583. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.4 Single axis mastering 586. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.5 Setting mastering data 589. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 Software Version 591. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.4 Robot Axis Status 593. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.5 Diagnosis Screen 599. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.1 Outline 599. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.2 About Reducer Diagnosis 599. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.3 Procedure 600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.4 Each item 601. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.6 World Frame Origin 604. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.7 I/O Module Setting 605. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.8 Positioner setup 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.9 Extended Axis Setup 616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.10 Extended Axis Setup 621. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.11 Independent Additional Axis Board (Nobot) Startup Procedure 626. . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. ALARM CODES 630. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.1 Description of an Alarm Code Table 631. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.2 Alarm Codes 638. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D. SYSTEM VARIABLES 742. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.1 Format of a System Variable Table 743. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.2 System Variables 745. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B81524EN/01 1. INTRODUCTION

1

1. INTRODUCTION

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

Contents of this chapter

1.1 Manual Plan1.2 Workers1.3 General Safety Precautions1.4 Safety Precautions

1. INTRODUCTION B81524EN/01

2

1.1 Manual Plan

FANUC Robot series (RJ3i Mate CONTROLLER) LR HANDLING TOOL Operators Manual.

This manual describes how to operate the FANUC Robot LR Mate 100i MODEL B an allpurpose compact robot.It is controlled by the FANUC RJ3i Mate controller (called the robot controller hereinafter) containing the LRHandling tool software.

This manual describes the following items for versatile mini 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 manual

Each 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.

B81524EN/01 1. INTRODUCTION

3

Identification

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

Item to be checked Section

Edition of your software B.3 Software Version

Order No. of your software A.1 List of Menus

Specifications of products

For memory statuses or software option list, see the following sections:

Item to be checked Section

Memory status

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